Abstract:

A method of manufacturing a lock assembly for enabling use of a
key-in-knob lock cylinder assembly in different types of lock assemblies.
The method includes providing a key-in-knob lock assembly having a
key-in-knob housing and a plug rotatably engaged within the key-in-knob
housing, providing an interchangeable core lock assembly having an
interchangeable core housing, and inserting the key-in-knob housing into
the interchangeable core housing such that the key-in-knob housing is
universally exchangeable between the key-in-knob lock assembly and the
interchangeable core lock assembly.

Claims:

1. A method of manufacturing a lock assembly for enabling use of a
key-in-knob lock cylinder assembly in different types of lock assemblies,
the method comprising:providing a key-in-knob lock assembly including a
key-in-knob housing and a plug rotatably engaged within the key-in-knob
housing;providing an interchangeable core lock assembly including an
interchangeable core housing; andinserting the key-in-knob housing into
the interchangeable core housing such that the key-in-knob housing is
universally exchangeable between the key-in-knob lock assembly and the
interchangeable core lock assembly.

2. The method of claim 1, further comprising:providing a mortise lock
assembly including a mortise housing; andtransferring the key-in-knob
housing from the interchangeable core housing to the mortise housing such
that the key-in-knob housing is universally exchangeable between the key-
in-knob lock assembly, the interchangeable core lock assembly, and the
mortise lock assembly.

3. The method of claim 1, wherein the transferring step includesremoving
the key-in-knob housing from the interchangeable core housing;
andinserting the key-in-knob housing into the mortise housing.

4. The method of claim 2, further comprising:providing the mortise lock
assembly with a first housing portion and a second housing portion;
andinserting the key-in-knob housing into the first housing
portion;enclosing the key-in-knob housing in the mortise housing with the
second housing portion.

5. A method of manufacturing a lock assembly for enabling use of a
key-in-knob lock cylinder assembly in different types of lock assemblies,
the method comprising:providing a key-in-knob lock assembly including a
key-in-knob housing and a plug rotatably engaged within the key-in-knob
housing;providing a mortise lock assembly including a mortise housing;
andinserting the key-in-knob housing into the mortise housing such that
the key-in- knob housing is universally exchangeable between the
key-in-knob lock assembly and the mortise lock assembly.

6. The method of claim 5, further comprising:providing the mortise lock
assembly with a first housing portion and a second housing portion;
andinserting the key-in-knob housing into the first housing
portion;enclosing the key-in-knob housing in the mortise housing with the
second housing portion.

7. The method of claim 5, further comprising:providing an interchangeable
core lock assembly including an interchangeable core housing;
andtransferring the key-in-knob housing from the mortise housing to the
interchangeable core housing such that the key-in-knob housing is
universally exchangeable between the key-in-knob lock assembly, the
mortise lock assembly, and the interchangeable core lock assembly.

8. The method of claim 7, wherein the transferring step includesremoving
the key-in-knob housing from the mortise housing; andinserting the
key-in-knob housing into the interchangeable core housing.

9. A method of manufacturing a key-in-knob lock cylinder assembly for
enabling use of the key-in-knob lock cylinder assembly in different types
of lock assemblies, the method comprising:providing a key-in-knob lock
assembly including a key-in-knob housing and a plug rotatably engaged
within the key-in-knob housing;providing at least one of a mortise lock
assembly including a mortise housing and an interchangeable core lock
assembly including an interchangeable core housing; andexchanging at
least one of the key-in-knob housing and the plug between the key-
in-knob lock assembly, the mortise lock assembly, and the interchangeable
core lock assembly such that at least a portion of the key-in-knob lock
assembly is universally exchangeable between the key-in-knob lock
assembly, the mortise lock assembly, and the interchangeable core lock
assembly.

10. A key-in-knob lock cylinder assembly comprising:A key-in-knob housing
defining a cylindrical cavity, and an outer pin chamber communicating
with the cavity, the outer pin chamber being adapted to house an outer
pin; anda plug disposed in the cavity and being rotatable within the
cavity between a locked position and an unlocked position, the plug
having an inner pin chamber aligned with the outer pin chamber when the
plug is in the locked position;wherein at least one of the key-in-knob
housing and the plug is exchangeable between a key-in-knob lock assembly
and at least one of an interchangeable core lock assembly and a mortise
lock assembly.

11. The key-in-knob lock cylinder assembly of claim 9, further comprising
one of a cam and a tailpiece coupled to the key-in-knob plug, wherein
each of the cam and the tailpiece is exchangeable between the key-in-knob
lock assembly and at least one of the interchangeable core lock assembly
and the mortise lock assembly.

12. An interchangeable lock assembly comprising:an interchangeable core
housing having a housing body defining cavity with a figure-eight cross
section, and a locking hole extending into the housing body from adjacent
an upper portion of the cavity;an interchangeable core lock cylinder
assembly includinga key-in-knob housing having a wall defining a hollow
portion, and a pin portion defining at least two outer pin chambers
receiving outer pins,a plug having a body rotatably housed within the
hollow portion of the housing, a key slot disposed at least partially
through the body, at least two inner pin chambers disposed within the
body and in communication with the key slot, the at least two inner pin
chambers receiving inner pins, the plug further having a pin receiving
chamber receiving a control pin, andan actuating mechanism engageable by
the control pin and having an actuating pin holder, an actuating ring, an
actuating pin engageable with the locking hole, and a connector pin, the
actuating pin holder having a holder body, an insertion guide, and an
insertion channel extending partially through the holder body, the
actuating pin holder removably engaged with the pin portion via the
insertion channel such that the actuating pin holder is removably secured
to the key-in-knob housing.

13. The interchangeable core lock assembly of claim 12, wherein the pin
receiving chamber is in communication with the key slot and offset from
the at least two inner pin chambers such that the pin receiving chamber
is not longitudinally aligned with the at least two inner pin chambers.

14. The interchangeable core lock assembly of claim 13, wherein the
control pin extends into the key slot and is engageable by a control key
after insertion of the control key into the key slot.

15. The interchangeable core lock assembly of claim 14, wherein the
actuating mechanism is movable between a locked position and an unlocked
position using the control key to selectively lock the interchangeable
core lock cylinder assembly into the interchangeable core housing.

16. The interchangeable core lock assembly of claim 12, wherein the
actuating pin holder includes a passageway offset from a longitudinal
center of the actuating pin holder and extending through the holder body,
and wherein a stop pin is disposed in the passageway and selectively
engageable with the actuating pin and by the connector pin to selectively
allow pivotal movement of the connector pin relative to the actuating pin
holder.

17. The interchangeable core lock assembly of claim 12, wherein the pin
portion includes an insertion slot, wherein the actuating pin holder
includes an insertion rail protruding into the insertion channel, and
wherein the insertion rail is engageable with the pin portion within the
insertion slot to attach the actuating pin holder to the key-in-knob
housing.

18. The interchangeable core lock assembly of claim 17, wherein the
insertion slot extends from an outer end of the pin portion toward the
wall, and wherein the insertion rail extends through the actuating holder
along a side of the insertion channel.

19. The interchangeable core lock assembly of claim 12, further comprising
a face plate engaged with the key-in-knob housing to removably secure the
actuating pin holder to the key-in-knob housing.

20. The interchangeable core lock assembly of claim 19, wherein the face
plate is integrally formed with the actuating pin holder.

21. The interchangeable core lock assembly of claim 19, wherein the face
plate is formed from a hardened material resistant to tampering.

22. The interchangeable core lock assembly of claim 19, further comprising
an anti- tamper plate disposed in the face plate and press fit into the
insertion guide to secure the actuating pin holder to the housing and to
resist tampering.

23. The interchangeable core lock assembly of claim 12, wherein the
actuating pin includes a first body portion having a first diameter and a
second body portion having a second diameter smaller than the first
diameter to avoid interference between the second body portion and a
portion of the housing body adjacent the locking hole when the actuating
pin is moved to an engaged position.

24. The interchangeable core lock assembly of claim 23, wherein the
actuating pin is biased into the locking hole.

25. The interchangeable core lock assembly of claim 12, wherein the
actuating ring is disposed on the plug and pivotable relative to the
key-in-knob housing via rotation of the plug.

26. The interchangeable core lock assembly of claim 25, wherein the
actuating ring is at least partially held on the plug by a screw cap.

27. The interchangeable core lock assembly of claim 12, wherein the
connector pin is coupled to the actuating ring to engage the actuating
pin to selectively move the actuating pin between an engaged position and
a disengaged position.

28. The interchangeable core lock assembly of claim 27, wherein the
connector pin is engageable by the control pin to move the connector pin
between a first position in which a portion of the connector pin is
substantially engaged with the actuating ring, and a second position in
which the portion of the connector pin is spaced a relatively small
distance from the actuating ring.

29. The interchangeable core lock assembly of claim 12, wherein the
actuating pin is disposed in a passageway of the actuating pin holder and
is defined by a shape conforming to the shape of the passageway to
minimize stress on the actuating pin holder and the actuating pin.

30. A mortise lock assembly for locking and unlocking a door having a
driver mechanism movable between a locked position and an unlocked
position, the mortise lock assembly comprising:a mortise housing
including a first housing portion defining a first cavity, and a second
housing portion defining a second cavity and attached to the first
housing portion;a mortise lock cylinder assembly including a key-in-knob
housing and a plug rotatably engaged within the key-in-knob housing, the
key-in-knob housing and the plug substantially disposed in the mortise
housing within each of the first cavity and the second cavity; anda cam
engaged with an end of the plug and including a lobe engageable with the
driver mechanism to move the driver mechanism between the locked position
and the unlocked position.

31. The mortise lock assembly of claim 30, wherein the plug includes a
first end portion and a second end portion, and a hole located adjacent
the second end portion and adapted to receive a fastener to attach the
cam to the plug.

32. The mortise lock assembly of claim 30, wherein the plug includes a
drive channel extending through and across an end of the plug transverse
to a longitudinal axis of the plug.

33. The mortise lock assembly of claim 32, wherein the cam further
includes a cylindrical portion and a cam drive element coupled to the
cylindrical portion, and wherein the cylindrical portion is engaged with
a portion of the second cavity of the second housing portion to align the
cam with the plug.

34. The mortise lock assembly of claim 33, wherein the cam drive element
is engaged with the drive channel to transfer rotation of the plug to the
cam.

35. The mortise lock assembly of claim 33, wherein the cam drive element
includes a key relief recess for providing relief between a key an the
cam when the key is inserted into the plug.

36. A lock assembly comprising:an assembly housing defining a cavity;a
lock cylinder assembly including a housing and a plug rotatably engaged
within the housing, the housing and the plug substantially disposed in
the assembly housing within the cavity;an extension engaged with an end
of the plug; anda cam engaged with the extension such that the plug is
operable with assembly housings having different lengths.

37. The lock assembly of claim 36, wherein the plug includes a hole
located adjacent the end of the plug, and wherein the hole is adapted to
receive a fastener to attach the cam and the extension to the plug.

38. The lock assembly of claim 36, wherein the extension includes a key
relief recess to provide relief between a key and the extension when the
key is inserted into the plug.

39. The lock assembly of claim 36, wherein the plug includes a drive
channel extending through the end of the plug transverse to a
longitudinal axis of the plug.

40. The lock assembly of claim 39, wherein the extension includes an
extension drive element engaged with the drive channel to indirectly
attach the cam to the plug so that rotation of the plug is transferred to
the cam via the extension.

41. The lock assembly of claim 40, wherein the extension includes a drive
element slot extending diametrically across the extension opposite the
drive element, and wherein the cam includes a cam drive element coupled
to the drive element slot.

42. The lock assembly of claim 36, wherein the cam includes a cylindrical
portion, and wherein the cylindrical portion is engaged with the assembly
housing to align the cam with the plug.

43. The lock assembly of claim 42, wherein the cylindrical portion has an
inside diameter and the extension includes an outside diameter smaller
than the inside diameter of the cylindrical portion such that the
extension snugly fits into the cylindrical portion when the cam is
engaged with the extension.

44. A lock assembly comprising:a housing; anda lock cylinder assembly
including a rotatable plug, a single-piece cam member, and a retainer
clip, the cam member attached to the housing via the retainer clip and
having a lobe and a drive element engaged with the plug to transfer
rotation of the plug to the lobe, and the retainer clip having an arcuate
portion engaging the cam member to resist rotation of the cam member when
the lock cylinder assembly is removed from the housing.

45. The lock assembly of claim 44, wherein the housing includes an
aperture and a cam hole, and wherein the retainer clip extends through
the aperture to attach the cam member to the housing.

46. The lock assembly of claim 45, wherein the plug is accessible through
the cam hole, and wherein the drive element extends through the cam hole
to engage the plug.

47. The lock assembly of claim 44, further comprising an alignment pin
coupled to the plug, wherein the drive element includes opposed
engagement recesses defined by curved surfaces that are engageable by the
alignment pin to transfer rotation of the plug to the cam member.

48. The lock assembly of claim 44, wherein the drive element includes
opposed retainer slots and a clearance groove, and wherein the retainer
clip engages the drive element within the retainer slots.

49. The lock assembly of claim 48, wherein the clearance groove extends
through an outer surface of the drive element and is adapted to receive
an end of a retainer clip removal tool to detach the retainer clip from
the cam member.

50. The lock assembly of claim 49, wherein the retainer clip defines a
tool slot substantially aligned with the clearance groove when the
retainer clip is attached to the cam member.

51. The lock assembly of claim 44, wherein the retainer clip includes an
extension engaged with the cam member, and wherein the extension and the
arcuate portion cooperate to attach the cam member to the housing.

52. The lock assembly of claim 51, wherein the arcuate portion has a
curved surface profile engaged with the drive element.

53. A lock assembly comprising:a housing; anda lock cylinder assembly
including a rotatable plug, a single-piece cam member, and a retainer
clip, the cam member attached to the housing via the retainer clip and
having a lobe and a drive element engaged with the plug to transfer
rotation of the plug to the lobe, and the retainer clip having an
extension and an arcuate portion engaged with the cam member to attach
the cam member to the housing.

54. The lock assembly of claim 53, wherein the arcuate portion has a
curved surface profile engaged with the drive element to resist rotation
of the cam member when the lock cylinder assembly is removed from the
housing.

55. The lock assembly of claim 53, wherein the drive element has an
engagement recess, and wherein the extension is engaged with the drive
element within the engagement recess.

[0002]The invention relates to a lock assembly for a door. More
particularly, the invention relates to a lock assembly that includes a
housing and a plug.

[0003]Generally, some lock assemblies include a housing and a plug that
define respective pin chambers to receive pin pairs. The pin pairs
include outer pins substantially disposed within the housing, and inner
pins disposed within the plug. Springs are often used to bias the pin
pairs toward a key slot defined in the plug. More specifically, the
springs are engaged with the outer pins, which in turn engage the inner
pins and force the inner pins into the key slot. In the absence of a
correct or proper key, the outer pins are partially disposed in the plug
and block rotation of the plug within the housing.

[0004]The plug is rotatable relative to the housing in most conventional
lock cylinders. A shear line is defined where the plug and the housing
meet. When a proper key is inserted into the key slot, the inner pins are
moved. Movement of the inner pins moves the respective outer pins so that
the junctions of the inner pins and the outer pins are aligned with the
shear line. This allows the plug to be turned to an unlocked position
such that the outer pins are disposed completely in the housing, and the
inner pins are disposed completely in the plug.

[0005]Some existing lock assemblies include an interchangeable core that
has a housing and a plug that allow re-keying or replacement of the lock
assembly. Interchangeable core lock assemblies permit re-keying of locks
without opening the door or removing the lock from the door. Typically,
existing housings and plugs are designed specifically for a particular
lock type, and these interchangeable cores have mounting structure that
is also designed specifically for the lock type in which the
interchangeable core is used. Existing interchangeable cores are
relatively complicated and are often manufactured using complex machining
and manufacturing processes. For example, a knob lock assembly, a lever
lock assembly, and deadbolt lock assembly each utilize a particular
interchangeable core. These arrangements often complicate re-keying
and/or replacement of the lock assembly.

[0006]Existing mortise lock assemblies include a one-piece housing that is
inserted into an opening in a door or other structure, and that is
engaged with a mortise chassis in the door to lock and unlock the door.
These lock assemblies also include multiple anti-drill pins to limit
tampering with the lock assembly, and a plug that is specifically sized
for the mortise housing. To accommodate doors that have different
thicknesses, existing mortise lock assemblies require multiple housings
and plugs that are sized to conform to different door thicknesses. In
particular, each housing and plug in existing mortise lock assemblies are
designed to fit one door thickness, and cannot be used in lock assemblies
that are applied to a door of a different thickness.

[0007]Some existing lock assemblies include a cam attached to the housing
assembly and to a separate driver that is disposed in the housing
assembly to move a latch between a locked position and an unlocked
position. Often, a washer spaces the driver from the cam, and the cam is
attached to the driver by a separate screw. Typically, the driver and the
screw are inserted into the housing assembly through an opening in the
front of the housing assembly. The cam is engaged with a rear of the
housing assembly, and is attached to the driver using the screw.

[0008]During operation of the lock assemblies that include the cam, the
driver is rotated by the plug, which in turn causes rotation of the cam
to move the latch between the locked and unlocked positions. Often, the
screw is loosened by operation of the lock assembly, which can disengage
the cam from the driver. Disengagement of the cam from the driver can
prevent the cam from moving the driver between the locked and unlocked
positions. In some lock assemblies, a friction washer and/or a thread
adhesive applied to the screw can be used to temporarily delay loosening
of the cam from the housing assembly.

SUMMARY

[0009]The invention provides a method of manufacturing lock assemblies
that enables a key-in-knob lock cylinder assembly to be used in different
types of lock assemblies. For example, the method can include providing a
key-in-knob lock assembly that has a key-in-knob housing and a plug that
is rotatably engaged within the key-in-knob housing. The method also
includes providing an interchangeable core ("IC") lock assembly that
includes an IC housing, and inserting the key-in-knob housing into the IC
housing such that the housing is universally exchangeable between the
key-in-knob lock assembly and the IC lock assembly.

[0010]As another example, the method can include providing the key-in-knob
lock assembly that has the key-in-knob housing and the plug, and
providing a mortise lock assembly that includes a mortise housing, and
inserting the key-in-knob housing into the mortise housing such that the
housing is universally exchangeable between the key-in-knob lock assembly
and the mortise lock assembly.

[0011]In yet another aspect, the invention provides a key-in-knob lock
cylinder assembly and apparatus that enables use of at least portions of
the lock cylinder assembly in different types of lock assemblies, e.g.,
interchangeable core and mortise lock assemblies. The method of
manufacturing a lock assembly for enabling use of a key-in-knob lock
cylinder assembly in different types of lock assemblies includes
providing a key-in-knob lock assembly including a key-in-knob housing and
a plug rotatably engaged within the key-in-knob housing, and providing at
least one of a mortise lock assembly including a mortise housing and an
interchangeable core lock assembly including an interchangeable core
housing. The method also includes exchanging at least one of the
key-in-knob housing and the plug between the key-in-knob lock assembly,
the mortise lock assembly, and the interchangeable core lock assembly
such that at least a portion of the key-in-knob lock assembly is
universally exchangeable between the key-in-knob lock assembly, the
mortise lock assembly, and the interchangeable core lock assembly.

[0012]In yet another aspect, the key-in-knob lock cylinder assembly
includes a key-in-knob housing defining a cylindrical cavity, and an
outer pin chamber communicating with the cavity that is adapted to house
an outer pin. The key-in-knob lock assembly also includes a plug disposed
in the cavity and rotatable within the cavity between a locked position
and an unlocked position. The plug has an inner pin chamber that is
aligned with the outer pin chamber when the plug is in the locked
position. At least one of the key-in-knob housing and the plug is
exchangeable between the key-in-knob lock assembly and at least one of an
interchangeable core lock assembly and a mortise lock assembly

[0013]In yet another aspect, the invention provides an IC lock assembly
that includes an IC housing and an IC lock cylinder assembly. The IC
housing includes a housing body defining cavity having a figure-eight
cross section, and a locking hole that extends into the housing body from
adjacent an upper portion of the cavity. The IC lock cylinder assembly
includes a key-in- knob housing and a plug. The housing includes a wall
that defines a hollow portion, and a pin portion that defines at least
two outer pin chambers that receive outer pins. The plug includes a body
that is rotatably housed within the hollow portion of the housing, a key
slot that is disposed at least partially through the body, at least two
inner pin chambers that are disposed within the body and in communication
with the key slot that receive inner pins, and a pin receiving chamber
that receives a control pin. The IC lock cylinder assembly also includes
an actuating mechanism that is engageable by the control pin. The
actuating mechanism includes an actuating pin holder, an actuating ring,
an actuating pin that is engageable with the locking hole, and a
connector pin. The actuating pin holder has a holder body, an insertion
channel that extends partially through the holder body, and an insertion
guide. The actuating pin holder is removably engaged with the pin portion
via the insertion channel such that the actuating pin holder is removably
secured to the key-in-knob housing.

[0014]In yet another aspect, the invention provides a mortise lock
assembly for locking and unlocking a door having a driver mechanism that
is movable between a locked position and an unlocked position. The
mortise lock assembly includes a mortise housing, and a mortise lock
cylinder assembly that has a key-in-knob housing and a plug that is
rotatably engaged within the key-in-knob housing. The mortise housing
includes a first housing portion that defines a first cavity, and a
second housing portion that defines a second cavity and that is attached
to the first housing portion. The key-in-knob housing and the plug are
substantially disposed in the mortise housing within each of the first
cavity and the second cavity. The mortise lock assembly also includes a
cam that is engaged with an end of the plug and that includes a lobe that
is engageable with the driver mechanism to move the driver mechanism
between the locked position and the unlocked position.

[0015]In yet another aspect, the invention provides a lock assembly that
includes an assembly housing defining a cavity, and a lock cylinder
assembly that has a housing and a plug that is rotatably engaged within
the housing. The housing and the plug are substantially disposed in the
assembly housing within the cavity. The lock assembly also includes an
extension that is engaged with an end of the plug, and a cam that is
engaged with the extension such that the plug is operable with housings
that have different lengths.

[0016]In yet another aspect, the invention provides a lock assembly that
includes a housing, a lock cylinder assembly having a plug, a
single-piece cam member, and a retainer clip. The cam member is attached
to the housing via the retainer clip. The cam member includes a lobe and
a drive element that is engaged with the plug to transfer rotation of the
plug to the lobe. The retainer clip includes an arcuate portion that
engages the cam member to resist rotation of the cam member when the lock
cylinder assembly is removed from the housing.

[0017]In yet another aspect, the invention provides a lock assembly that
includes a housing and a lock cylinder assembly having a plug, a
single-piece cam member, and a retainer clip. The cam member is attached
to the housing via the retainer clip. The cam member includes a lobe and
a drive element that is engaged with the plug to transfer rotation of the
plug to the lobe. The retainer clip has an extension and an arcuate
portion that are engaged with the cam member to attach the cam member to
the housing.

[0018]Other aspects of the invention will become apparent by consideration
of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1 is a perspective view of a lock assembly embodying the
invention and including a housing, a plug, and an appropriate key.

[0020]FIG. 2 is an exploded perspective view of the lock assembly of FIG.
1.

[0021]FIG. 3 is a section view of the lock assembly of FIG. 1 taken along
line 3-3.

[0022]FIG. 4 is a side view of a key blank for the appropriate key of FIG.
1.

[0075]Before any embodiments of the invention are explained in detail, it
is to be understood that the invention is not limited in its application
to the details of construction and the arrangement of components set
forth in the following description or illustrated in the following
drawings. The invention is capable of other embodiments and of being
practiced or of being carried out in various ways. Also, it is to be
understood that the phraseology and terminology used herein is for the
purpose of description and should not be regarded as limiting. The use of
"including," "comprising," or "having" and variations thereof herein is
meant to encompass the items listed thereafter and equivalents thereof as
well as additional items. Unless specified or limited otherwise, the
terms "mounted," "connected," "supported," and "coupled" and variations
thereof are used broadly and encompass both direct and indirect
mountings, connections, supports, and couplings. Further, "connected" and
"coupled" are not restricted to physical or mechanical connections or
couplings.

[0076]FIG. 1 shows a lock assembly 10 for use with structures (e.g., door,
access panel, portable locks, etc.) that may be locked and unlocked.
Hereinafter, the term "door" shall be used to represent all such lockable
structures and shall not be construed to limit the invention's
application solely to doors. The lock assembly 10 that is illustrated in
FIG. 1 is a key-in-knob ("KIK") lock assembly that is lockable and
unlockable using an appropriate key 15. As illustrated in FIG. 4, the key
15 is formed from a key blank 20 that includes a head portion 25 and a
key portion 30. As illustrated in FIG. 3, the key portion 30 is shaped or
cut to include pin engaging portions 35 that are formed along the length
of the key portion 30.

[0077]FIGS. 1 and 2 show that the KIK lock assembly 10 includes a housing
40 and a plug 45 that is selectively rotatable within the housing 40
using the appropriate key 15. As shown in FIG. 3, the housing 40 and the
plug 45 cooperate with each other to define a shear line 50. FIGS. 2 and
5 show that the housing 40 includes a first end 55, a second end 60, a
wall 65 and a pin portion 70. The wall 65 includes a substantially
cylindrical portion that defines a hollow portion 75 that receives the
plug 45. As illustrated in FIG. 5, the wall 65 also includes a
substantially planar or flat outer surface 77 at a bottom of the housing
40 that extends from the first end 55 to the second end 60. In other
constructions, the wall 65 may have a cylindrical shape without the flat
outer surface 77. The housing 40 is typically fixed relative to the door,
and the plug 45 is rotatable relative to the housing 40 within the hollow
portion 75 between a locked position and an unlocked position.

[0078]As shown in FIGS. 2, 3, and 5, the pin portion 70 extends above the
wall 65 and includes exterior surfaces 80, insertion slots 85, a pin
cover channel 90, and first or outer pin chambers 95. The insertion slots
85 are disposed in the exterior surfaces 80, and extend along the length
of the pin portion 70 between the first end 55 and the second end 60. In
other constructions, the pin portion 70 may include insertion slots that
extend from an outside end of the pin portion 70 toward the wall 65.

[0079]FIG. 3 shows that the outer pin chambers 95 are accessible through a
cover strip 100 that is positioned adjacent the outer end of the pin
portion 70 in the pin cover channel 90. As illustrated in FIG. 3, the
outer pin chambers 95 extend inward into the pin portion 70 from adjacent
the outer end of the pin portion 70. The pin portion 70 includes six
outer pin chambers 95, but fewer or more outer pin chambers 95 are within
the scope of the invention.

[0080]FIGS. 2 and 3 show that the plug 45 includes a body 105 that is
rotatable relative to the housing 40 within the hollow portion 75. The
body 105 is defined by a first end portion 110, a second end portion 115,
and an outer surface 120. The first end portion 110 is accessible from
the front of the KIK lock assembly 10. The second end portion 115 is
accessible from the rear of the KIK lock assembly 10. FIG. 1 shows that
the plug 45 includes two pin holes 125 (one shown) that extend into the
plug 45 from the second end portion 115, and that are located
diametrically opposite each other.

[0081]The plug 45 also includes a key slot 130 and second or inner pin
chambers 135. The key slot 130 extends longitudinally through the body
105 from the first end portion 110 toward the second end portion 115, and
is further accessible from adjacent the first end portion 110.

[0082]The inner pin chambers 135 extend from the outer surface 120 of the
body 105 toward the key slot 130 substantially perpendicular to the key
slot 130. The inner pin chambers 135 are in communication with the key
slot 130, and are further selectively aligned with respective outer pin
chambers 95 upon insertion of the plug 45 into the housing 40. FIG. 2
shows that the plug 45 includes six inner pin chambers 135. While the
outer and inner pin chambers 95, 135 are shown as substantially
cylindrical chambers, they can have other shapes (e.g., rectangular,
etc.) that are within the scope of the invention.

[0083]FIGS. 2 and 3 show that the pin portion 70 further includes a
respective first or outer pin 140 disposed within each of the outer pin
chambers 95. The outer pins 140 are configured to move in a first or
inward direction (downward in FIG. 3) into the plug 45, and in a second
or outward direction (upward in FIG. 3) away from the plug 45. Generally,
the outer pins 140 extend partially into the respective inner pin
chambers 135 when the plug 45 is in the locked position and the
appropriate key 15 is not inserted into the slot. The pin portion 70
further includes springs 145 to bias the outer pins 140 inward. In other
constructions, the outer pins 140 may tend to move inward without the
springs 145. In some constructions, the outer pins 140 can move inward
without engagement by the springs 145 due to orientation of the pin
portion 70 above the plug 45 (i.e., inward movement is assisted by
gravity).

[0084]FIGS. 2 and 3 show that a respective second or inner pin 150 is
disposed within each of the inner pin chambers 135. Each inner pin 150
can have a length that is the same as or different from the length of the
other inner pins 150. Each of the inner pins 150 is selectively engaged
with the respective outer pin, and the cover strip 100 is disposed in the
pin cover channel 90 to retain the outer pins 140, the inner pins 150,
and the springs 145 within the housing 40 and the plug 45. Each of the
inner pins 150 includes an end portion 155 that extends into the key slot
130, and that is engageable by the key 15 after insertion of the key 15
into the key slot 130. Each end portion 155 of the inner pins 150 can be
defined by a tapered cone, or alternatively, by other shapes (e.g.,
semispherical end, etc.).

[0085]Generally, the quantity of inner pins 150 will be the same as the
quantity of outer pins 140. In the illustrated construction, the pin
portion 70 includes six outer pins 140 and six inner pins 150. However
more or fewer outer pins 140 and inner pins 150 may be possible and are
within the scope of the invention. For example, commercial applications
of the plug 45 usually include six outer and inner pins 140, 150,
respectively, in accordance with established industry practices. However,
residential applications of the plug 45 usually have settled on five
outer and inner pins 140, 150, respectively. In these residential
applications, the plug 45 may include five outer pins 140 and inner pins
150 in five corresponding outer and inner pin chambers 95, 135, even
though the plug 45 may have six or more outer and inner pin chambers 95,
135. The remaining outer and inner pin chambers 95, 135 may be unused in
residential applications. The invention described herein incorporates
both commercial and residential applications of the lock assembly 10, and
should not be limited to only one such application.

[0086]FIGS. 1-3 show that the KIK lock assembly 10 also includes a
retainer or screw cap 160 and a driver bar or tailpiece 165. The screw
cap 160 is attached to the second end portion 115 of the plug 45 to
rotatably couple the tailpiece 165 to the plug 45 so that a latch (not
shown) can be moved relative to the door by a driver mechanism (not
shown) to lock or unlock the door. More particularly, the screw cap 160
includes a cylindrical wall 170 that is inwardly threaded to threadably
engage the body 105 adjacent the second end portion 115. As shown in FIG.
1, the screw cap 160 also includes a circumferential end wall 175 that
extends radially inward along the cylindrical wall 170. The end wall 175
has a plurality of grooves or arcuate recesses 180 that are equally
spaced circumferentially along the inner portion of the end wall 175.

[0087]The tailpiece 165 is attached to the plug 45 via the screw cap 160,
and extends into the door. The tailpiece 165 includes a pin engagement
portion 185 and a bar 190. The pin engagement portion 185 includes two
pin slots 195 that are located diametrically opposite each other, and
that are generally aligned with at least one of the pin holes 125 when
the tailpiece 165 is attached to the plug 45. The bar 190 is coupled to
the pin engagement portion 185, and engages the driver mechanism to move
the latch between the locked position and the unlocked position.

[0088]An alignment pin 200 is disposed in one of the pin holes 125 to
align the plug 45 and the tailpiece 165. The alignment pin 200 is an
elongated member that includes tapered or reduced-diameter ends 205 that
define shoulders 210 of the alignment pin 200. A spring 215 is disposed
in the pin hole 125 in which the alignment pin 200 is disposed to bias
the alignment pin 200 toward the second end portion 115 of the plug 45.
One shoulder 210 of the alignment pin 200 is engaged by the spring 215,
and the other shoulder 210 is engaged with the end wall 175 of the screw
cap 160. The alignment pin 200 is also engaged with one of the plurality
of arcuate recesses 180 of the screw cap 160 to secure the screw cap 160
to the plug 45, and to align the plug 45, the screw cap 160, and the
tailpiece 165 relative to each other. The alignment pin 200 also
transfers rotation of the plug 45 to the tailpiece 165 so that the door
can be locked and unlocked.

[0089]In operation of the KIK lock assembly 10, the springs 145 bias the
outer pins 140 and the inner pins 150 inward such that the outer pins 140
partially extend into the inner pin chambers 135 without the appropriate
key 15 in the key slot 130. Generally, the inner pins 150 are in
communication with the key slot 130 for selective engagement by a key
(e.g., the key 15) that is inserted into the key slot 130. When the
appropriate key 15 is inserted into the key slot 130, the pin engaging
portions 35 engage the inner pins 150 to move the outer pins 140 to the
shear line 50. The plug 45 is rotated to lock or unlock the door after
the outer pins 140 are aligned with the shear line 50, which rotates the
screw cap 160 and the tailpiece 165 to move the latch between the locked
and unlocked positions.

[0090]FIGS. 6-23 show another construction of a lock assembly 310 for use
with the door. Except as described below, the lock assembly 310 is
similar to the lock assembly 10 described with regard to FIGS. 1-5, and
common elements are given the same reference numerals. The lock assembly
310 that is illustrated in FIGS. 6-23 is an interchangeable core ("IC")
lock assembly that is lockable and unlockable using an appropriate key
315 (FIG. 11) that is similar to the key 15.

[0091]As illustrated in FIGS. 6, 9, and 10, the lock assembly 310 includes
an IC housing 320 and an IC lock cylinder assembly 325. FIGS. 6 shows
that the IC housing 320 includes a rim 330 and a housing body 335 that
extends from the rim 330. The rim 330 abuts a surface of the door, and
the housing body 335 engages the inside of the door.

[0092]FIGS. 6 and 8 show that the IC housing 320 also includes a first
interior surface 340, a second interior surface 345, and a locking hole
350. The first interior surface 340 and the second interior surface 345
cooperate with each other and intersect to define a cavity 355 that has a
substantially "figure-eight" shaped cross-section. As illustrated in FIG.
8, each of the first interior surface 340 and the second interior surface
345 is generally cylindrical, and the cavity 355 extends completely
through the IC housing 320. As viewed in FIG. 8, the first interior
surface 340 is disposed generally below the second interior surface 345.

[0093]The locking hole 350 extends into the IC housing 320 from the second
interior surface 345 adjacent the end of the housing body 335 that is
opposite the rim 330. The locking hole 350 is generally
cylindrically-shaped, although other shapes of the locking hole 350 are
considered herein.

[0094]The IC lock cylinder assembly 325 is insertable into the IC housing
320 within the cavity 355, and is generally held in place by the first
and second interior surfaces 340, 345. FIGS. 9-11 show that the lock
cylinder assembly 325 includes the housing 40 and a plug 360 that is
selectively rotatable within the housing 40. Upon insertion of the IC
lock cylinder assembly 325 into the IC housing 320, the housing 40 is
fixed relative to the IC housing 320 and the door, and the plug 360 is
movable relative to the housing 40 between a locked position and an
unlocked position using the key 315 that has pin engaging portions 365.
The wall 65 of the housing 40 is substantially engageable with the first
interior surface 340 when the IC lock cylinder assembly 325 is disposed
in the cavity 355.

[0095]A control key 370 is used to lock and unlock the IC lock cylinder
assembly 325 relative to the IC housing 320. FIG. 12 shows that the
control key 370 is formed from a key blank 375 that includes a head
portion 380 and a key portion 385. Generally, the key portion 385 of the
control key 370 is shaped or cut to include the pin engaging portions
365. The control key 370 is further shaped to include a projection 390 on
the end of the key portion 385.

[0096]As shown in FIG. 11, the housing 40 and the plug 360 cooperate with
each other to define a shear line 395. The outer pin chambers 95 are
accessible through a cover strip 400 that is positioned in the pin cover
channel 90 adjacent the outer end of the pin portion 70.

[0097]Except as described below, the plug 360 is similar to the plug 45
that is described with regard to FIGS. 1-5, and common elements are given
the same reference numerals. FIGS. 13 and 14 show that the plug 360
includes a body 405 that is rotatable relative to the hollow portion 75
of the housing 40. The body 405 is defined by the first end portion 110,
the second end portion 115, and the outer surface 120.

[0098]FIGS. 9 and 14 show that the plug 360 also includes the pin holes
125, the key slot 130, the inner pin chambers 135, a pin receiving
chamber 410, and anti-tamper holes 412. Generally, the inner pin chambers
135 are longitudinally aligned with each other between the first end
portion 110 and the second end portion 115, and the inner pins 150 are
disposed within each of the inner pin chambers 135. The cover strip 400
is disposed in the pin cover channel 90 to retain the outer and inner
pins 140, 150 and the springs 145 within the housing 40 and the plug 360.

[0099]The pin receiving chamber 410 is proximate to the second end portion
115, and is offset from the inner pin chambers 135 such that the pin
receiving chamber 410 is not longitudinally aligned with the inner pin
chambers 135 along the outer surface 120. The pin receiving chamber 410
is in communication with the key slot 130. FIGS. 11 and 21-23 show that a
control pin 415 is disposed in the pin receiving chamber 410. The control
pin 415 can have a length that is the same as or different from the
length of the inner pins 150. The control pin 415 extends into the key
slot 130, and is engageable by the projection 390 of the control key 370
after insertion of the control key 370 into the key slot 130. The end of
the control pin 415 can be defined by a tapered cone, or alternatively,
by other shapes (e.g., semispherical end, etc.).

[0100]FIGS. 13 and 14 show that the anti-tamper holes 412 are disposed in
the plug 360 adjacent the first end portion 110 on opposite sides of the
key slot 130. The anti-tamper holes 412 receive anti-tamper pins 417,
which are resistant to drilling or other tampering methods and cooperate
with the plug 360 to inhibit removal of the plug from the IC lock
assembly 310.

[0101]FIG. 10 shows that the IC lock cylinder assembly 325 also includes
the screw cap 160, the tailpiece 165, the alignment pin 200, the spring
215, an actuating mechanism 420, and a face plate 422. The actuating
mechanism 420 is coupled to the housing 40 and the plug 360, and is
movable between a locked position and an unlocked position using the
control key 370. When the actuating mechanism 420 is in the locked
position, the IC lock cylinder assembly 325 is locked into the IC housing
320 so that the IC lock cylinder assembly 325 cannot be removed from the
IC housing 320 without the control key 370. When the actuating mechanism
420 is in the unlocked position, the IC lock cylinder assembly 325 is
removable from the IC housing 320.

[0102]FIGS. 10 and 17 show that the actuating mechanism 420 includes an
actuating pin holder 425, an actuating pin 430, an actuating ring 435, a
connector pin 440, and a stop pin 445. FIGS. 15 and 16 show that the
actuating pin holder 425 includes a holder body 450 that has a first or
insertion end 455, a second or actuating end 460, and two insertion arms
465 that are attached to each other adjacent the actuating end 460. The
insertion arms 465 extend from the actuating end 460 toward the insertion
end 455 substantially parallel to each other.

[0103]The insertion arms 465 are spaced apart from each other and include
exterior surfaces 470 and interior surfaces 475. The exterior surfaces
470 extend between the insertion end 455 and the actuating end 460, and
substantially engage a portion of the second interior surface 345 of the
IC housing 320 when the lock cylinder assembly 325 is inserted into the
cavity 355. The interior surfaces 475 define an insertion channel 480
that extends partially longitudinally through the holder body 450, and
that is accessible from adjacent the insertion end 455. The insertion
channel 480 is substantially enclosed at one end by the actuating end
460. The pin portion 70 is disposed in the insertion channel 480 when the
lock cylinder assembly 325 is assembled such that the outer pin chambers
95 are accessible through the actuating pin holder 425.

[0104]Each insertion arm 465 also includes an insertion rail 485 and an
insertion guide 490. The insertion rail 485 protrudes from the interior
surface 475 into the insertion channel 480, and extends along the length
of the insertion channel 480. The actuating pin holder 425 is attachable
to the housing 40 by engaging each insertion rail 485 with the respective
insertion slot 85 on the pin portion 70.

[0105]The insertion guides 490 are formed on the ends each of the
insertion arms 465 adjacent the insertion end 455. Each insertion guide
490 includes a rib or protrusion 495 that cooperates with a portion of
the holder body 450 to define a guide recess 500. In the illustrated
construction, the protrusion 495 has substantially flat surfaces. In
other constructions, the protrusion 495 can include curved or rounded
surfaces. In still other constructions, the protrusion 495 may include
one or more slanted surfaces. Similarly, in some constructions, the guide
recess 500 can be defined by substantially flat surfaces. In other
constructions, the guide recess 500 can be defined by one or more curved
or rounded surfaces. In still other constructions, the guide recess 500
may be defined by one or more slanted surfaces.

[0106]FIGS. 15 and 16 show that the actuating end 460 connects the
insertion arms 465 to each other to form the unitary actuating pin holder
425. The actuating end 460 includes an upper portion that has a shallow
groove or channel 505 that is defined by a surface 507 and that receives
a portion of the cover strip 400, and a lower portion that is defined by
a substantially cylindrical surface 510. As illustrated in FIG. 8, the
shallow channel 505 is defined by a substantially flat surface 507. The
cover strip 400 is coupled to the actuating end 460 and to the outer end
of the pin portion 70 in the pin cover channel 90 to retain the outer
pins 140, the inner pins 150, and the springs 145 in the housing 40 and
the plug 360.

[0107]The actuating pin holder 425 also includes a first bore or
passageway 515 and a second bore or passageway 520. FIGS. 15-17 show that
the first passageway 515 has a cylindrical shape, and extends into the
pin holder body 450 adjacent the actuating end 460 from one of the
exterior surfaces 470 partially through the actuating pin holder 425
toward the other exterior surface 470. The first passageway 515 is
oriented substantially perpendicular to the insertion channel 480, and
receives the actuating pin 430. FIGS. 16 and 17 show that the first
passageway 515 is in communication with the lower portion of the
actuating end 460 such that a portion of the first passageway is exposed.
In the illustrated construction, the first passageway 515 is
substantially horizontal when the IC lock assembly 310 is inserted into
the door.

[0108]FIGS. 16 and 17 show that the second passageway 520 is offset from a
longitudinal center of the actuating pin holder 425, and extends through
the holder body 450 from the surface 507 that defines the shallow channel
505 to the cylindrical surface 510. The second passageway 520 is oriented
substantially perpendicular to the first passageway 515 such that the
second passageway 520 intersects the first passageway 515. In the
illustrated construction, the second passageway 520 is oriented
substantially when the IC lock assembly 310 is inserted into the door.

[0109]FIG. 18 shows the actuating pin 430, the actuating ring 435, and the
connector pin 440 prior to assembly. FIG. 17 shows that the actuating pin
430 is disposed in the first passageway 515. In the illustrated
construction, the actuating pin 430 is substantially cylindrically-shaped
to conform to the shape of the first passageway 515. Other shapes of the
actuating pin 430 are also possible and considered herein. Generally, the
cylindrical shape of the actuating pin 430 ensures surface contact
between the actuating pin holder 425 and the actuating pin 430 to
minimize stress on the actuating pin holder 425 and the actuating pin
430.

[0110]The actuating pin 430 includes a first body portion 530 that has a
first diameter, and a second body portion 535 that has a second diameter
that is smaller than the first diameter, defining a transition or
shoulder 540. Generally, the actuating pin 430 is movable within the
first passageway 515 between an engaged position that engages the second
body portion 535 with the locking hole 350, and a disengaged position
that disengages the second body portion 535 from the locking hole 350.
The illustrated second body portion 535 is smaller than the first body
portion 530 to avoid interference between the second body portion 535 and
the portion of the second interior surface 345 that is adjacent the
locking hole 350 when the actuating pin 430 is moved to the engaged
position. In other constructions, the second diameter of the second body
portion 535 can be the same as the first diameter of the first body
portion 530, without the shoulder 540.

[0111]FIG. 17 shows that the first body portion 530 includes a spring
recess 545. A spring 550 is disposed in the first passageway 515. One end
of the spring 550 is engaged with the interior end of the first
passageway 515 of the actuating pin holder 425, and the other end of the
spring is engaged with the actuating pin 430 within the spring recess 545
to bias the actuating pin 430 to the engaged position.

[0112]FIGS. 17 and 18 show that the actuating pin 430 also includes a bore
555 that extends completely through the first body portion 530 proximate
to the middle of the first body portion 530. An upper portion of the bore
555 defines an engagement recess 560 that receives the stop pin 445. The
actuating pin 430 is insertable into the first passageway 515 and
slidable within the first passageway 515 between the disengaged position
and the engaged position such that the bore 555 is substantially aligned
with the second passageway 520 when the actuating mechanism 420 is in the
engaged position.

[0113]FIGS. 9 and 21-23 show that the actuating ring 435 is coupled to the
housing 40 and the plug 360. The actuating ring 435 is rotatable or
pivotable relative to the housing 40 via rotation of the plug 360. In the
illustrated construction, the angle of rotation of the actuating ring 435
relative to the housing 40 is approximately 12 degrees. In other
constructions, the angle of rotation of the actuating ring 435 relative
to the housing 40 can be more or less than 12 degrees.

[0114]FIG. 18 shows that the actuating ring 435 includes a ring body
portion 565 and a pin receiving portion 570. The ring body portion 565
and the pin receiving portion 570 define a transition that receives the
upper end of the control pin 415 after the control pin 415 is engaged by
the control key 370. The ring body portion 565 has a substantially hollow
cylindrical shape to receive the second end portion 115 of the plug 360,
and is at least partially held onto the lock cylinder assembly 325 by the
screw cap 160.

[0115]The pin receiving portion 570 is coupled to the ring body portion
565 at an apex of the actuating ring 435, and is engaged with the
cylindrical surface 510. FIGS. 21-23 show that the pin receiving portion
570 is in communication with the actuating pin 430. FIG. 10 shows that
the pin receiving portion 570 includes a pin bore 575 that extends
completely through the pin receiving portion 570. When the actuating
mechanism 420 is assembled, the pin receiving portion 570 is engaged with
the actuating pin holder 425, and is pivotable along the cylindrical
surface 510.

[0116]The connector pin 440 is disposed in the pin bore 575 of the
actuating ring 435 to engage the actuating pin 430 to selectively move
the actuating pin 430 between the engaged position and the disengaged
position. FIG. 18 shows that the connector pin 440 includes a pin head
portion 580 that has a first diameter, and an elongated portion 585 that
is coupled to the pin head portion 580 and that has a second diameter
that is smaller than the first diameter. The elongated portion 585 is
disposed in the pin bore 575 of the pin receiving portion 570. As
illustrated in FIGS. 21-23, the pin head portion 580 extends upward from
the elongated portion 585 into the bore 555 of the actuating pin 430. The
connector pin 440 is engageable by the control pin 415 to move the
connector pin 440 between a first position in which the pin head portion
580 is substantially engaged with the pin receiving portion 570, and a
second position in which the pin head portion 580 is spaced a relatively
small distance from the pin head portion 580.

[0117]FIGS. 11, 17, and 21-23 show that the stop pin 445 and a spring 590
are disposed in the second passageway 520 of the actuating pin holder
425. The stop pin 445 is engageable with the engagement recess 560 of the
actuating pin 430 to limit movement of the actuating pin 430 between the
disengaged position and the engaged position. The stop pin 445 is
substantially cylindrical, and includes a spring recess portion 595 that
receives an end of the spring 590. The spring 590 is engaged with the
cover strip 400 and with the stop pin 445 within the spring recess
portion 595 to bias the stop pin 445 toward the actuating pin 430 and the
engagement recess 560.

[0118]FIG. 9 shows that the face plate 422 is attached to the actuating
pin holder 425 adjacent the forward end of the housing 40 to secure the
actuating pin holder 425 to the pin portion 70. As illustrated in FIGS.
19 and 20, the face plate 422 includes a substantially cylindrical body
600 that has a curved surface 605 and a pin holder attachment portion
610. The cylindrical body 600 engages the second interior surface 345
when the lock cylinder assembly 325 is inserted into the cavity 355. The
curved surface 605 substantially corresponds to the curvature of the
first end portion 110 of the plug 360, and engages the first end portion
110 when the face plate 422 is attached to the actuating pin holder 425.
The face plate 422 is formed from a hardened material (e.g., steel,
aluminum, etc.) that is resistant to drilling or other tampering methods.

[0119]The pin holder attachment portion 610 includes guide attachment
members 615, a recessed surface 620, and sidewalls 625 that interconnect
the guide attachment members 615 and the recessed surface 620. The guide
attachment members 615, the recessed surface 620, and the sidewalls 625
cooperate to define a partially enclosed insertion groove 630 that
extends from the curved surface 605 partially into the cylindrical body
600. When the face plate 422 is attached to the actuating pin holder 425,
the insertion guides 490 are substantially engaged with the insertion
groove 630, and each guide attachment member 615 is substantially engaged
with the associated guide recess 500 of the insertion arms 465.
Generally, the insertion guides 490, the insertion groove 630, the guide
recesses 500, and the guide attachment members 615 cooperate with each
other to securely attach the actuating pin holder 425 to the pin portion
70, and limit access to the pin portion 70 from outside the IC lock
assembly 310.

[0120]FIG. 11 shows the IC lock assembly 310 with the appropriate key 315
inserted into the key slot 130 of the plug 360. The pin engaging portions
365 of the appropriate key 315 are engaged with each of the inner pins
150 to move the outer pins 140 to the shear line 395 without engaging the
control pin 415. Once the outer pins 140 are moved to the shear line 395,
the plug 360 can be rotated between the locked and unlocked positions.

[0121]The lock cylinder assembly 325 is assembled by inserting the plug
360 into the housing 40 after the inner pins 150, the control pin 415,
and the anti-tamper pins 417 have been positioned in the plug 360. The
plug 360 is assembled by inserting the inner pins 150 into the inner pin
chambers 135, and by inserting the control pin 415 into the pin receiving
chamber 410. The outer pins 140 are positioned in the outer pin chambers
95 after the plug 360 has been assembled and inserted into the housing
40. The springs 145 are inserted into the pin portion 70 after insertion
of the outer pins 140 to bias the outer pins 140 and the inner pins 150
inward such that the outer pins 140 partially extend into the inner pin
chambers 135.

[0122]The actuating ring 435 is rotatably attached to the second end
portion 115 of the plug 360 and the actuating ring 435 is engaged with
the outer surface 120 of the plug 360 and with the wall of the housing 40
after the plug 360 is inserted into the housing 40. The tailpiece 165 is
engaged with the plug 360 inside the ring body portion 565. Generally,
one of the pin slots of the tailpiece 165 is aligned with one of the
holes in the plug 360 and with one of the plurality of arcuate recesses
in the screw cap 160 during attachment of the screw cap 160 to the plug
360. The spring 215 is inserted into the associated hole of the plug 360
before the tailpiece 165 is attached to the plug 360. The screw cap 160
is threaded onto the second end portion 115 of the plug 360 to attach the
tailpiece 165 to the plug 360, and secures the actuating ring 435 to the
plug 360 so that the actuating ring 435 is permitted to pivot about the
outer surface 120 of the plug 360 without axial movement of the actuating
ring 435.

[0123]When the tailpiece 165 abuts the second end portion 115 and is
securely sandwiched between the plug 360 and the screw cap 160, the
alignment pin 200 is inserted into the associated pin hole 125 of the
plug 360. The alignment pin 200 engages the pin slot of the tailpiece 165
to maintain alignment of the plug 360 and the tailpiece 165, and to
rotationally attach the screw cap 160 and the tailpiece 165 to the plug
360. The outward shoulder 210 of the alignment pin 200 is engaged with
the arcuate recess 180 of the screw cap 160 to retain the alignment pin
200 within the pin hole 125.

[0124]The actuating pin holder 425 is assembled onto the housing 40 by
engaging the insertion rail 485 with the insertion slots on the pin
portion 70 so that the actuating end 460 abuts the pin portion 70. The
outer end of the pin portion 70 extends through the insertion channel
480. When the actuating pin holder 425 is assembled onto the housing 40
and the actuating ring 435 is coupled to the plug 360, the pin receiving
portion 570 of the actuating ring 435 is disposed proximate to and
substantially engaged with the cylindrical surface 510.

[0125]The face plate 422 is attached to the actuating pin holder 425 by
sliding the insertion guides 490 of the actuating pin holder 425 into the
insertion groove 630. When the face plate 422 is attached to the
actuating pin holder 425, the curved portion of the face plate 422 abuts
the first end portion 110 of the plug 360, and access to the pin portion
70 is substantially limited.

[0126]The actuating pin 430 and the spring 550 can be inserted into the
first passageway 515 before or after the actuating pin holder 425 is
attached to the housing 40. The pin bore 575 is substantially aligned
with the second passageway 520 and the pin receiving chamber 410 after
the actuating pin 430 is inserted into the first passageway 515 so that
the connector pin 440 can be inserted through the second passageway 520,
into the bore 555 of the actuating pin 430, and into the pin bore 575 of
the actuating ring 435. The elongated portion 585 extends into the pin
receiving chamber 410 into communication with the control pin 415, and
the pin head portion 580 is substantially engaged with the pin receiving
portion 570 and substantially disposed in the bore 555 of the actuating
pin 430 after the connector pin 440 is inserted into the actuating pin
holder 425 and the actuating ring 435. The connector pin 440 couples the
actuating ring 435 to the actuating pin 430 such that pivotal movement of
the actuating ring 435 moves the actuating pin 430 laterally between the
engaged position and the disengaged position. The first passageway 515
allows pivotal movement of the connector pin 440 relative to the
actuating pin holder 425.

[0127]The locking assembly is inserted into the second passageway 520
after the connector pin 440 is inserted into second passageway 520. The
stop pin 445 is engaged with the actuating pin 430 within the engagement
recess 560, and the spring 590 is engaged with the stop pin 445. The
cover strip 400 is positioned in the shallow channel 505 of the actuating
pin holder 425 and over the outer pin chambers 95 in the pin receiving
channel after assembly of the housing 40, the plug 360, and the actuating
mechanism 420.

[0128]FIGS. 24-33 show another construction of an IC lock cylinder
assembly 725 for use with the lock assembly 310. Except as described
below, the IC lock cylinder assembly 725 is the same as the IC lock
cylinder assembly 325 described with regard to FIGS. 6-23, and common
elements are given the same reference numerals.

[0129]FIGS. 24-26 show that the IC lock cylinder assembly 725 includes the
plug 360 and a housing 730. The plug 360 is selectively rotatable within
the housing 730. Upon insertion of the IC lock cylinder assembly 725 into
the IC housing 320, the housing 730 is fixed relative to the IC housing
320 and the door, and the plug 360 is movable relative to the housing 730
between a locked position and an unlocked position using the key 315. As
shown in FIG. 26, the plug 360 and the housing 730 cooperate with each
other to define the shear line 395.

[0130]The housing 730 is similar to the housing 40 described with regard
to FIGS. 1-23. FIG. 27 shows that the housing 730 includes a first end
735, a second end 740, a wall 745 and a pin portion 750. The wall 745 is
substantially engageable with the first interior surface 340 when the IC
lock cylinder assembly 725 is disposed in the cavity 355, and includes a
substantially cylindrical portion that defines a hollow portion 752 that
receives the plug 360.

[0131]The pin portion 750 extends above the wall 745 and defines a step
753 disposed adjacent the second end 740. The pin portion 750 includes
exterior surfaces 755 (one shown), insertion slots 760, a pin cover
channel 765, first or outer pin chambers 770, and an insertion guide 775.
The insertion slots 760 are disposed in the exterior surfaces 755 and
extend generally vertically downward (as viewed in FIG. 27) from the
outer end of the pin portion 750 toward the wall 745. As shown in FIGS.
25-27, the outer pin chambers 770 are accessible through the cover strip
400 that is positioned in the pin cover channel 765. The outer pin
chambers 770 extend inward into the pin portion 750 from adjacent the
outer end of the pin portion 750. The insertion guide 775 is formed on
the end of the pin portion 750 adjacent the first end 735. The insertion
guide 775 is defined by a recess that extends through the pin portion 750
between the exterior surfaces 755.

[0132]FIGS. 25 and 26 show that the IC lock cylinder assembly 725 also
includes the screw cap 160, the tailpiece 165, the alignment pin 200, the
spring 215, the connector pin 415, an actuating mechanism 780, and an
anti-tamper plate 785. The actuating mechanism 780 is coupled to the
housing 730 and the plug 360, and is movable between a locked position
and an unlocked position using the control key 370. Like the actuating
mechanism 420, when the actuating mechanism 780 is in the locked
position, the IC lock cylinder assembly 725 is locked into the IC housing
320 so that the IC lock cylinder assembly 725 cannot be removed from the
IC housing 320 without the control key 370. When the actuating mechanism
780 is in the unlocked position, the IC lock cylinder assembly 725 is
removable from the IC housing 320.

[0133]The actuating mechanism 780 includes the actuating ring 435, the
actuating pin 430, the connector pin 440, the stop pin 445, the spring
590 (see FIGS. 17 and 26), and an actuating pin holder 790. FIGS. 25, 28,
and 29 show that the actuating pin holder 790 includes a first or
faceplate end 800, a second or actuating end 805, and two insertion arms
810 that extend between the first end 800 and the second end 805
substantially parallel to each other. The faceplate end 800 and the
actuating end 805 are fixed relative to the insertion arms 810 to connect
the insertion arms 810 to each other to form the unitary actuating pin
holder 790.

[0134]Generally, the faceplate end 800 limits access to the pin portion
750 from outside the IC lock assembly 310. The faceplate end 800 defines
a face plate 812 that has a faceplate surface 815 adjacent the first end
735 of the housing 730. The faceplate end 800 is substantially
cylindrically-shaped and has a curved surface 820 and a plate recess or
slot 825. The cylindrically-shaped faceplate end 800 engages the second
interior surface 345 when the lock cylinder assembly 725 is inserted into
the cavity 355. The curved surface 820 substantially corresponds to the
curvature of the first end portion 110 of the plug 360, and engages the
first end portion 110 when the actuating pin holder 790 is coupled to the
housing 730.

[0135]The plate recess 825 is spaced a distance from the faceplate surface
815 and extends laterally through the faceplate end 800. The plate recess
825 defines an attachment slot 830 adjacent a central portion of the
plate recess 825. In some constructions, the plate recess 825 may extend
partially through the faceplate end 800 from one side of the actuating
pin holder 790.

[0136]FIG. 26 shows that the actuating end 805 is positioned around the
housing 730 adjacent the step 753. The step 753 provides clearance
between the pin portion 750 and the actuating end 805 so that the housing
730 and the actuating pin holder 790 can be coupled together. As shown in
FIG. 28, the actuating end 805 includes an upper portion that has a
shallow groove or channel 835 that is defined by a surface 840 and that
receives a portion of the cover strip 400. As shown in FIG. 29, a lower
portion of the actuating end 805 is defined by a substantially
cylindrical surface 845. The cover strip 400 is coupled to the actuating
end 805 and to the outer end of the pin portion 750 in the pin cover
channel 765 to retain the outer pins 140, the inner pins 150, and the
springs 145 in the housing 730 and the plug 360.

[0137]The insertion arms 810 are spaced apart from each other and include
exterior surfaces 850 and interior surfaces 855. The exterior surfaces
850 extend between the faceplate end 800 and the actuating end 805, and
substantially engage a portion of the second interior surface 345 of the
IC housing 320 when the lock cylinder assembly 325 is inserted into the
cavity 355. The interior surfaces 855 define an insertion channel 860
that extends through the actuating pin holder 790 between the faceplate
end 800 and the actuating end 805. The pin portion 750 is disposed in the
insertion channel 860 when the lock cylinder assembly 725 is assembled
such that the outer pin chambers 770 are substantially accessible through
the actuating pin holder 790.

[0138]FIGS. 28 and 29 show that each insertion arm 810 also includes an
insertion rail 865 protruding from the interior surface 855 into the
insertion channel 860 and extending through the actuating pin holder 790
between an upper side of the insertion arm and a lower side of the
insertion arm. In other words, the insertion rails 865 extend
substantially vertically through the actuating pin holder 790 as viewed
in FIG. 28. The actuating pin holder 425 is attachable to the housing 730
by engaging the insertion rails 865 with the respective insertion slots
760 on the pin portion 750.

[0139]The actuating pin holder 790 also includes a first bore or
passageway 870 that is defined by a cylindrical shape that receives the
actuating pin 430, and a second bore or passageway 875 that receives the
stop pin 445 and the spring 590. In other constructions, the first
passageway 870 may be at least partially defined by other shapes (e.g.,
truncated cylindrical shape, rectangular shape, triangular shape, etc.).
The remaining characteristics and features of the first passageway 850
and the second passageway 875 are the same as the characteristics and
features of the first passageway 515 and the second passageway 520
described with regard to FIGS. 6-23, and will not be discussed in detail.

[0140]FIGS. 30 and 31 show another actuating pin 795 for use with the IC
lock cylinder assembly 725. The actuating pin 795 may be disposed in the
first passageway 870 in constructions of the actuating pin holder 790 in
which the first passageway 870 has a truncated cylindrical shape. The
actuating pin 795 is defined by a truncated cylindrical shape that
ensures surface contact between the actuating pin holder 790 and the
actuating pin 795 when the first passageway 870 is defined by a truncated
cylindrical shape to minimize stress on the actuating pin holder 790 and
the actuating pin 795. The remaining characteristics and features of the
actuating pin 795 are the same as the characteristics and features of the
actuating pin 430 described with regard to FIGS. 6-23, and will not be
discussed in detail.

[0141]As illustrated in FIGS. 32 and 33, the anti-tamper plate 785 is
insertable into the plate recess 825, and includes a plate portion 880
and an attachment boss 885 that extends across the plate portion. The
plate portion 880 and the attachment boss 885 generally conform to the
shape of the plate recess 825. The plate portion 880 has curved outer
surfaces 890 that conform to the curvature of the faceplate end 800.

[0142]The attachment boss 885 is engageable with the attachment slot 830,
and is further engageable with the insertion guide 775 to securely attach
the actuating pin holder 790 to the housing 730. For example, in some
constructions, the attachment boss 885 may be press fit into the
insertion guide 775 to securely hold the actuating pin holder 790 on the
pin portion 750. As shown in FIG. 33, the attachment boss 885 is tapered
from a first size adjacent one side of the plate portion 880 to a smaller
size adjacent the other side of the plate portion 880 to allow insertion
and removal of the anti-tamper plate 785 relative to the plate recess
825. The larger portion of the attachment boss 885 is in close-fitting
(e.g., press fit) relationship with the insertion guide 775 and the
attachment slot 830. The anti-tamper plate 785 is formed from a hardened
material (e.g., steel, aluminum, etc.) that is resistant to drilling or
other tampering methods. Generally, the faceplate end 800 and the
anti-tamper plate 785 cooperate with each other to limit access to the
pin portion 750 from outside the IC lock assembly 310.

[0143]Except as described below, assembly of the IC lock cylinder assembly
725 is the same as assembly of the IC lock cylinder assembly 325
described with regard to FIGS. 6-23.

[0144]The actuating pin holder 790 is assembled onto the housing 730 by
engaging the insertion rails 865 with the insertion slots 760 on the pin
portion 750 so that the faceplate end 800 and the actuating end 805 abut
the respective ends of the pin portion 750. The outer end of the pin
portion 750 extends through the insertion channel 860. When the actuating
pin holder 790 is assembled onto the housing 730 and the actuating ring
435 is coupled to the plug 360, the pin receiving portion 570 of the
actuating ring 435 is disposed proximate to and substantially engaged
with the cylindrical surface 845.

[0145]The anti-tamper plate 785 is attached to the actuating pin holder
790 by sliding the anti-tamper plate 785 into the plate recess 825. The
attachment boss 885 is aligned and engaged with the attachment slot 830
upon insertion of the anti-tamper plate 785 into the plate recess 825.
The attachment boss 885 is further tightly engaged with the insertion
guide 775, securing the actuating pin holder 790 to the housing 730. When
engaged with the plate recess 825, the anti-tamper plate 785 resists
removal of the actuating pin holder 790 from the housing 730 via the
attachment boss 885, which inhibits vertical movement of the actuating
pin holder 790 relative to the housing 730. The curved outer surfaces 890
conform to the curvature of the faceplate end 800 and the curved portion
of the faceplate end 800 abuts the first end portion 110 of the plug 360,
and access to the pin portion 750 is substantially limited.

[0146]Except as described below, operation of the IC lock assembly 310 is
similar to the operation KIK lock assembly 310 described with regard to
FIGS. 1-5. Generally, the IC lock cylinder assembly 325 or the IC lock
cylinder assembly 725 may be inserted into the IC housing 320. Operation
of the IC lock assembly 310 including the IC lock cylinder assembly 725
is the same as operation of the IC lock assembly 310 including the IC
lock cylinder assembly 325. For the sake of brevity, only operation of
the IC lock assembly 310 including the IC lock cylinder assembly 325 will
be described herein.

[0147]The IC lock cylinder assembly 325 is secured to the IC housing 320
using the actuating mechanism 420. The control key 370 is inserted into
the key slot 130 to engage the control pin 415 and to move the actuating
pin 430 between the engaged position and the disengaged position.

[0148]FIG. 20 shows the IC lock cylinder assembly 325 prior to insertion
into the IC housing 320, and prior to insertion of the control key 370 or
the appropriate key into the key slot 130. As illustrated in FIG. 20, the
IC lock cylinder assembly 325 is in a normal position that is defined by
the actuating pin 430 positioned in the engaged position and the outer
and inner pins 140, 150 biased inward by the springs 145. The control pin
415 is disposed in the key slot 130 and completely within the plug 360
after the IC lock cylinder assembly 325 is assembled. In the normal
position, the actuating pin 430 is biased outward from the actuating pin
holder 425 by the spring 550, and the bore 555 of the actuating pin 430
is substantially aligned with the second passageway 520. The stop pin 445
is biased into engagement with the engagement recess 560 by the spring
590, which in turn biases the connector pin 440 downward into engagement
with the pin receiving portion 570 and the control pin 415.

[0149]FIG. 21 shows the IC lock cylinder assembly 325 with the control key
370 inserted into the key slot 130. The control key 370 controls movement
of the outer and inner pins 140, 150, as well as movement of the
actuating mechanism 420 via the control pin 415. When the control key 370
is inserted into the key slot 130, the pin engaging portions engage the
inner pins 150 to move the outer pins 140 to the shear line 395. The
projection of the control key 370 engages the control pin 415 and moves
the control pin 415 into engagement with the connector pin 440. The
connector pin 440 is moved by the control pin 415 into engagement with
the stop pin 445, which in turn moves the stop pin 445 out of the
engagement recess 560.

[0150]As illustrated in FIG. 22, after the stop pin 445 and the actuating
pin 430 are no longer engaged with each other, the actuating pin 430 can
be moved from the engaged position to the disengaged position for
insertion of the IC lock cylinder assembly 325 into the IC housing 320.
FIG. 22 illustrates the IC lock cylinder assembly 325 in a control
position. The control key 370 is rotated in a first direction (e.g.,
clockwise) to move the actuating pin 430 from the engaged position to the
disengaged position. Rotational movement of the control key 370 rotates
the plug 360 and the actuating ring 435, and rotation of the actuating
ring 435 is translated to linear motion of the actuating pin 430. After
the actuating pin 430 is moved to the disengaged position, the IC lock
cylinder assembly 325 is inserted into the IC housing 320.

[0151]When the IC lock cylinder assembly 325 is disposed within the IC
housing 320, the control key 370 is rotated in a second direction (e.g.,
counter-clockwise) to rotate the plug 360 and the actuating ring 435,
which translates to linear movement of the actuating pin 430 from the
disengaged position to the engaged position. The actuating pin 430 is
engaged with the locking hole 350 to secure the IC lock cylinder assembly
325 in the IC housing 320. Rotation of the control key 370 in the second
direction adjusts the IC lock cylinder assembly 325 from the control
position to the normal position, and the control key 370 can be removed
from the key slot 130 after the IC lock cylinder assembly 325 is
repositioned in the normal position. In other words, the control key 370
can be removed from the key slot 130 after the IC lock cylinder is locked
in the IC housing 320.

[0152]The appropriate key can be inserted into the key slot 130 to move
the plug 360 between the locked and unlocked positions. Like the pin
engaging portions of the control key 370, the pin engaging portions of
the appropriate key engage the inner pins 150 to move the outer pins 140
to the shear line 395. Unlike the control key 370, the appropriate key
does not engage the control pin 415, and therefore cannot engage the
actuating pin 430. The plug 360 is rotated to lock or unlock the door
after the outer pins 140 are aligned with the shear line 395, which in
turn rotates the screw cap 160 and the tailpiece 165 to move the deadbolt
between the locked and unlocked positions.

[0153]The desired locking characteristics of the IC lock assembly 310 can
be varied by replacing the IC lock cylinder assembly 325 with different
IC lock cylinder assemblies within the IC housing 320. Use of different
lock cylinder assemblies with the same IC housing 320 allows relatively
quick change of the locking characteristics without replacement of the
entire lock assembly 310. The process for replacing the IC lock cylinder
assembly 325 with a second IC lock cylinder assembly 325 is accomplished
by reversing the order of the steps described above with regard to FIGS.
20-22. More particularly, the control key 370 is inserted into the key
slot 130 of the assembled lock assembly 310 to engage the inner pins 150
and the connector pin 440, and the connector pin 440 is moved by the
control key 370 into the bore 555 of the actuating pin 430.

[0154]As described above, after the control key 370 is inserted into the
key slot 130, the IC lock cylinder assembly 325 is adjusted from the
normal position to the control position to move the actuating pin 430
from the engaged position to the disengaged position, which removes the
actuating pin 430 from the locking hole 350. After the IC lock cylinder
assembly 325 is removed from the IC housing 320, the second IC lock
cylinder assembly 325 can be inserted into the IC housing 320 using the
same process described above with regard to FIGS. 20-22, which will not
be described in detail. In this manner, the lock cylinder assembly 325 of
the lock assembly 310 can be easily and relatively quickly changed to
alter the locking characteristics of the lock assembly 310 without
professional assistance.

[0155]FIGS. 34-47 show another construction of a lock assembly 1010 for
use with the door. Except as described below, the lock assembly 1010 is
similar to the lock assembly 10 that is described with regard to FIGS.
1-5, and common elements are given the same reference numerals. The lock
assembly 1010 that is illustrated in FIGS. 34-47 is a mortise lock
assembly that is lockable and unlockable using an appropriate key 1015
that is similar to the key 15, and that includes pin engaging portions
1020 (FIGS. 40 and 41). Generally, the mortise lock assembly 1010
cooperates with a mortise chassis (not shown) that is disposed in the
door to lock and unlock the door.

[0156]FIGS. 34 and 35 show that the mortise lock assembly 1010 includes a
mortise housing 1025, a lock cylinder assembly 1030, an extension 1035,
and a cam 1040. In the illustrated construction, the mortise lock
assembly 1010 also includes an anti-tamper plate 1045. The anti- tamper
plate 1045 is formed from a hardened material (e.g., steel, aluminum,
etc.) that is resistant to drilling or other tampering methods, and
generally conforms to the shape of the mortise housing 1025. In other
constructions, the mortise lock assembly 1010 may be provided without an
anti-tamper plate.

[0157]The mortise housing 1025 has a first housing portion 1050 and a
second housing portion 1055 that is attached to the first housing portion
1050 with fasteners 1057 (e.g., screws, bolts, etc.). The first housing
portion 1050 defines a front or forward portion of the mortise housing
1025. FIGS. 36 and 37 show that the first housing portion 1050 includes a
first end 1065 that has a rim 1070 abutting the door and accessible from
outside the door, and a second end 1075 having a substantially
cylindrical first housing body portion 1080 that extends from the rim
1070 into the door. The first housing body portion 1080 extends into the
door when the mortise lock assembly 1010 is attached to the door, and
includes an outer surface 1085, an end surface 1095, and a cavity 1100.
The outer surface 1085 is engageable with an interior portion of the
door.

[0158]In constructions of the mortise lock assembly 1010 that include the
anti-tamper plate 1045, the anti-tamper plate 1045 is disposed in an
anti-tamper slot 1090 adjacent the first end 1065 of the first housing
portion 1050. In these constructions, the anti-tamper slot 1090 is
recessed inward from the outer surface 1085 into the first housing body
portion 1080 (i.e., generally downward as viewed in FIG. 37) adjacent the
first end 1065, and is in communication with the cavity 1100. In
constructions of the mortise lock assembly 1010 without an anti-tamper
plate, the first housing portion 1050 may not include the anti-tamper
slot 1090.

[0159]As illustrated in FIGS. 36 and 37, the cavity 1100 includes a first
cavity portion 1105 that extends completely through the first housing
portion 1050, a second cavity portion 1110 that extends from the second
end 1075 toward the first end 1065, and a recess portion 1115 that
extends into the first housing body portion 1080 adjacent the first end
1065. The first cavity portion 1105 and the second cavity portion 1110
are in communication with each other and generally cooperate to conform
to the shape of the lock cylinder assembly 1030. The illustrated first
cavity portion 1105 is defined by a cylindrical surface 1120 and a
substantially planar surface 1125 that is opposite the second cavity
portion 1110 adjacent the bottom of the first cavity portion 1105.

[0160]The first cavity portion 1105 is accessible from adjacent the first
end 1065 and the second end 1075. FIG. 37 shows that the second cavity
portion 1110 extends from the end surface 1095 partially through the
first housing body portion 1080, and is defined by a substantially
rectangular-shaped cross section. The recess portion 1115 receives a face
plate (not shown) that is engaged with the first end 1065 of the first
housing portion 1050, and that is partially disposed in the recess
portion 1115 to retain the face plate on the mortise housing 1025.

[0161]The first housing portion 1050 also includes housing attachment
portions 1130 and first attachment channels 1135. The housing attachment
portions 1130 protrude outward from the end surface 1095, and include
threaded holes 1140 that receive ends of the fasteners 1057. The first
attachment channels 1135 are disposed in the outer surface 1085 of the
first housing portion 1050 and are spaced apart from each other by
approximately 180 degrees along the perimeter of the first housing body
portion 1080.

[0162]The first attachment channels 1135 extend longitudinally into the
first housing body portion 1080 from the second end 1075 toward the first
end 1065. The first attachment channels 1135 receive elongated screws or
other fasteners (not shown) of the mortise chassis to lock the mortise
housing 1025 from rotation after the mortise housing 1025 is engaged with
the mortise chassis.

[0163]FIGS. 35, 38, and 39 show that the second housing portion 1055
defines a back or rearward portion of the mortise housing 1025. The
second housing portion 1055 includes a first end 1145 that is attachable
to the first housing portion 1050, and a second end 1150 that is
positionable adjacent the mortise chassis. The second housing portion
1055 is defined by a substantially cylindrical second housing body
portion 1155 that includes an exterior surface 1160, a first cavity 1165,
a second cavity 1170, second attachment channels 1175, and holes 1180. In
some constructions, the exterior surface 1160 can be at least partially
threaded to threadably engage a threaded portion of the mortise chassis
(not shown).

[0164]FIGS. 38 and 39 show that the first cavity 1165 extends through the
second housing portion 1055 from the first end 1145 to the second end
1150. The first cavity 1165 is in communication with the second cavity
1170 to receive a portion of the lock cylinder assembly 1030, and to
further receive the cam 1040 and the extension 1035. The first cavity
1165 includes a cylindrical surface 1185 and a substantially flat surface
1190. The lock cylinder assembly 1030 is substantially engaged with the
second housing portion 1055 within the first cavity 1165.

[0165]FIG. 38 shows that the second cavity 1170 is recessed into the
second housing portion 1055 from the first end 1145. The second cavity
1170 extends partially through the second housing body portion 1155, and
is defined by symmetrical curved surfaces 1195 and a substantially
rectangular cavity portion 1205. The curved surfaces 1195 are disposed on
each side of the rectangular cavity portion 1205. The opposed curved
surfaces 1195 cooperate to conform to the shape of the housing attachment
portions 1130 so that the second housing portion 1055 can be attached to
the first housing portion 1050 without a gap between the first and second
housing portions 1050, 1055. The rectangular cavity portion 1205 is
recessed into the second housing portion 1055 to conform to the shape of
an upper portion of the lock cylinder assembly 1030. The second cavity
1170 is in communication with the first cavity 1165 adjacent a transition
wall 1210.

[0166]FIGS. 34, 38, and 39 show that the second attachment channels 1175
are disposed in the exterior surface 1160 of the second housing portion
1055. The second attachment channels 1175 are spaced apart from each
other by approximately 180 degrees along the perimeter of the second
housing body portion 1155. The second attachment channels 1175 extend
from the first end 1145 to the second end 1150 completely through the
second housing portion 1055, and are aligned with the first attachment
channels 1135 of the first housing portion 1050 to receive the elongated
fasteners of the mortise chassis to lock the mortise housing 1025 from
rotation after the mortise housing 1025 is engaged with the mortise
chassis.

[0167]The holes 1180 extend into the second housing body portion 1155 from
adjacent the second end 1150, and are in communication with the second
cavity 1170. As illustrated in FIG. 38, the holes 1180 are partially
defined by counter bores 1215 adjacent the second end 1150 so that ends
of the fasteners 1057 can be recessed within the second housing portion
1055 and oriented substantially flush with the second end 1150. When the
second housing portion 1055 is attached to the first housing portion
1050, the holes 1180 are in communication with the holes 1140 of the
first housing portion 1050 to facilitate attachment of the second housing
portion 1055 to the first housing portion 1050 using the fasteners 1057.

[0168]FIG. 35 shows that the lock cylinder assembly 1030 is insertable
into the first housing portion 1050 within the cavity 1100, and is also
insertable into the second housing portion 1055 within the first cavity
1165 and the second cavity 1170. FIGS. 35, 40, and 41 show that the lock
cylinder assembly 1030 includes the housing 40 and a plug 1220 that is
selectively rotatable within the housing 40. The housing 40 that is
illustrated in FIG. 40 is longer than the housing 40 illustrated in FIG.
41. Other than the length, the housings 40 shown in FIGS. 40 and 41 are
the same.

[0169]The flat outer surface 77 of the housing 40 engages the planar
surface 1125 and engages the flat surface 1190 when the lock cylinder
assembly 1030 is inserted into the first and second housing portions
1050, 1055. Upon insertion of the lock cylinder assembly 1030 into the
mortise housing 1025, the housing 40 is fixed relative to the mortise
housing 1025 and the door, and the plug 1220 is movable relative to the
housing 40 and the mortise housing 1025 between a locked position and an
unlocked position using the key 1015.

[0170]As shown in FIGS. 40 and 41, the housing 40 and the plug 1220
cooperate with each other to define a shear line 1225. The outer pin
chambers 95 are accessible through the cover strip 100 that is positioned
in the pin cover channel 90 adjacent the outer end of the pin portion 70.

[0171]Except as described below, the plug 1220 is similar to the plug 45
that is described with regard to FIGS. 1-5, and common elements are given
the same reference numerals. In some constructions, the plug 1220 is the
same as the plug 45.

[0172]FIGS. 42 and 43 show that the plug 1220 includes a body 1230 that is
rotatable relative to the housing 40. The body 1230 is defined by the
first end portion 110, the outer surface 120, and a second end portion
1235. A longitudinal axis 1245 extends through the plug 1220 from the
first end portion 110 to the second end portion 1235. The first end
portion 110 is accessible from the front of the mortise lock assembly
1010. The second end portion 1235 is accessible from the rear of the
mortise lock assembly 1010. In some constructions, the second end portion
1235 is unthreaded. In other constructions, the second end portion 1235
may be threaded.

[0173]FIGS. 40-43 show that the plug 1220 includes the key slot 130, the
inner pin chambers 135, a first hole 1250, a second hole 1255, and a
drive channel 1260 that is located adjacent the second end portion 1235.
The inner pins 150 are disposed within each of the inner pin chambers
135. The cover strip 100 is disposed in the pin cover channel 90 to
retain the outer pins 140, the springs 145, and the inner pins 150 within
the housing 40 and the plug 1220. The first hole 1250 is a locator hole
that is positioned adjacent the outer surface 120.

[0174]FIG. 43 shows that the second hole 1255 is located adjacent the
outer surface 120 of the plug 1220 and spaced apart from the first hole
1250. The second hole 1255 is further spaced apart or offset from the
longitudinal axis 1245 of the plug 1220. In some constructions, the
second hole 1255 includes threads that are threadably engaged by a
fastener 1262 (e.g., bolt, screw, etc.) (FIGS. 34 and 35). In other
constructions, the second hole 1255 may be unthreaded.

[0175]FIG. 43 shows that the drive channel 1260 extends through the second
end portion 1235 across the body 1230 transverse or perpendicular to the
longitudinal axis 1245. The drive channel 1260 is partially defined by a
recessed surface 1265. In the illustrated construction, the recessed
surface 1265 is substantially planar such that drive channel 1260 is
defined by a substantially rectangular cross-section. In other
constructions, the drive channel 1260 can include other cross-sectional
shapes. The second hole 1255 extends into the body 1230 from the recessed
surface 1265.

[0176]FIGS. 34 and 40 shows that the cam 1040 is engageable with the plug
1220 via the extension 1035 adjacent the second end portion 1235. In some
constructions, the cam 1040 is directly engaged with the plug 1220
without the intervening extension 1035 (FIG. 41). Generally, the
extension 1035 is an optional component of the mortise lock assembly 1010
that cooperates with the cam 1040 to provide locking capability of the
lock cylinder assembly 1030 when the housing 40 has a relatively long
length (e.g., 1.375 inches, 1.5 inches, 1.625 inches, 1.75 inches, etc.).
In other words, the extension 1035 extends the length of the plug 1220 so
that the plug 1220 can engage the mortise chassis to lock and unlock the
door. In constructions of the lock cylinder assembly 1030 that include a
relatively short housing 40, the extension 1035 is not necessary to
extend the length of the plug 1220 (FIG. 41). In these constructions, the
cam 1040 provides the desired locking capability of the lock cylinder
assembly 1030 without the extension 1035.

[0177]FIGS. 44 and 45 show that the extension 1035 includes an extension
body 1270 that has an outside diameter, and an extension drive element
1275 that extends from an end of the extension body 1270. FIG. 45 shows
that the extension drive element 1275 extends diametrically across the
extension body 1270. The extension drive element 1275 is engageable with
the drive channel 1260 to indirectly attach the cam 1040 to the plug 1220
so that rotation of the plug 1220 can be transferred to the cam 1040 via
the extension 1035.

[0178]The extension drive element 1275 includes opposed curved end
portions 1280 and a key relief recess 1285. The curved end portions 1280
extend beyond the outside diameter of the extension body 1270, and are
engageable with the first cavity 1165 of the second housing portion 1055
to align the extension 1035 with the plug 1220. The key relief recess
1285 is positioned adjacent a center of the extension drive element 1275
to provide relief between the key 1015 and the extension 1035 when the
key 1015 is inserted into the key slot 130 (FIG. 40).

[0179]As illustrated in FIGS. 44 and 45, the extension body 1270 also
includes a drive element slot 1290 and an extension hole 1295. The drive
element slot 1290 extends diametrically across the end of the extension
body 1270 that is opposite the extension drive element 1275. The drive
element slot 1290 is defined by a recessed surface 1297, and has a
generally rectangular cross-section. The extension hole 1295 extends
completely through the extension body 1270 and the extension drive
element 1275, and is aligned with the second hole 1255 of the plug 1220
when the mortise lock assembly 1010 is assembled. The fastener 1262
extends through the extension hole 1295 to attach the cam 1040 to the
plug 1220.

[0180]FIGS. 34, 40 and 41 show that the cam 1040 is rotatable with the
plug 1220 to transfer rotation from the plug 1220 to the mortise chassis.
FIGS. 46 and 47 show that the cam 1040 includes a cam body 1300, an
engagement member 1305, a lobe 1310, and a cam hole 1315. The engagement
member is supported on an end of the cam body 1300. FIG. 47 shows that
the engagement member 1305 includes a cylindrical portion 1320 that has
an inside diameter, and a cam drive element 1325 that is coupled to the
cylindrical portion 1320. The outside diameter of the extension body 1270
is smaller than the inside diameter of the cylindrical portion 1320 so
that the extension body 1270 snugly fits into the cylindrical portion
1320 when the cam 1040 is attached to the extension 1035. The cylindrical
portion 1320 is generally centered on the cam body 1300 such that the
perimeter of the cylindrical portion 1320 is disposed adjacent edges of
the cam body 1300. The cylindrical portion 1320 extends outward from the
cam body 1300, and is engaged with the first cavity 1165 of the second
housing portion 1055 so that the cam 1040 is aligned with the plug 1220.

[0181]The cam drive element 1325 is similar to the extension drive element
1275, and generally corresponds to the shape of the drive element slot
1290. When the cam 1040 is attached to the extension 1035, the cam drive
element 1325 is disposed in the drive element slot 1290 (FIG. 40). In
constructions of the mortise lock assembly 1010 that do not include the
extension 1035 (FIG. 41), the cam drive element 1325 is disposed directly
in the drive channel 1260 of the plug 1220 so that rotation of the plug
1220 is transferred to directly the cam 1040.

[0182]The cam drive element 1325 extends inward from the perimeter of the
cylindrical portion 1320 and laterally across the cam body 1300. The cam
drive element 1325 includes a key relief recess 1330 that is positioned
adjacent a center of the cam drive element 1325 to provide relief between
the key 1015 and the cam 1040 when the key 1015 is inserted into the key
slot 130. The key relief recess 1330 is similar to the key relief recess
1285 of the extension 1035.

[0183]The lobe 1310 extends outward from the cam body 1300 (i.e., upward
in FIGS. 46 and 47). The lobe 1310 is engageable with a driver mechanism
of the mortise chassis to move the latch and thereby lock and unlock the
door in response to rotation of the plug 1220.

[0184]The cam hole 1315 extends through the cam body 1300 offset from a
center of the cam 1040, and is partially defined by a counter bore 1335.
The cam hole 1315 further extends through the cam drive element 1325 so
that the fastener 1262 can extend through the cam 1040. The fastener 1262
extends through the cam hole 1315 to attach the cam 1040 to the plug 1220
so that movement of the cam 1040 is dependent on movement of the plug
1220. As illustrated in FIG. 40, in constructions that include the
extension 1035, the fastener 1262 also attaches the cam 1040 to the
extension 1035.

[0185]FIGS. 40 shows the mortise lock assembly 1010 with the appropriate
key 1015 inserted into the key slot 130. The pin engaging portions 1020
of the appropriate key 1015 are engaged with each of the inner pins 150
to move the outer pins 140 to the shear line 1225. After the outer pins
140 are moved to the shear line 1225, the plug 1220 can be rotated
between the locked and unlocked positions.

[0186]The mortise lock assembly 1010 is assembled by inserting the plug
1220 into the housing 40 after the inner pins 150 have been positioned in
the plug 1220, similar to the assembly of the KIK lock assembly 10. The
assembled lock cylinder assembly 1030 is inserted into the first and
second cavities of the second housing portion 1055. The second housing
portion 1055 and the lock cylinder assembly 1030 are attached to the
first housing portion 1050 by inserting the lock cylinder assembly 1030
into the cavity 1100. The plug 1220 is accessible through the first
cavity portion 1105, and the pin portion 70 of the housing 40 abuts the
end of the second cavity portion 1110. The second housing portion 1055 is
attached to the first housing portion 1050 using the fasteners 1057,
which are inserted through the holes 1180 of the second housing portion
1055 and into the holes 1140 defined by the housing attachment portions
1130 to rigidly secure the second housing portion 1055 to the first
housing portion 1050. The anti- tamper plate 1045, if included in the
mortise lock assembly 1010, can be inserted into the anti- tamper slot
1090 at any time during assembly of the mortise lock assembly 1010.

[0187]In constructions of the mortise lock assembly 1010 in which the
extension 1035 is included, the extension 1035 is engaged with the plug
1220 within the drive channel 1260. Next, the cam 1040 is engaged with
the extension 1035 via the engagement member 1305 and the drive element
slot 1290. The cylindrical portion 1320 is engaged with the extension
body 1270 when the cam 1040 is attached to the extension 1035. The
fastener 1262 is inserted through the extension and cam holes 1295, 1315
to attach the cam 1040 and the extension 1035 to the plug 1220.

[0188]Alternatively, in constructions in which the extension 1035 is not
included, the cam 1040 is directly engaged with the plug 1220 by
inserting the engagement member 1305 into the second cavity 1170, and
engaging the cam drive element 1325 with the drive channel 1260. In this
construction, the fastener 1262 is inserted through the cam hole 1315 to
attach the cam 1040 to the plug 1220. The assembled mortise lock assembly
1010 is threaded into the mortise chassis so that the lobe 1310 is
engaged with the driver mechanism.

[0189]Except as described below, operation of the mortise lock assembly
1010 is similar to the operation KIK lock assembly 10 that is described
with regard to FIGS. 1-5. Generally, the mortise lock cylinder assembly
1030 is inserted into the mortise housing 1025, as described above. When
the appropriate key 1015 is inserted into the key slot 130, the pin
engaging portions 1020 engage the inner pins 150 to move the outer pins
140 to the shear line 1225. The plug 1220 can be rotated after the outer
pins 140 are aligned with the shear line 1225, which in turn rotates the
extension 1035 and the cam 1040. Rotation of the cam 1040 engages the
lobe 1310 with the driver mechanism to move the latch between the locked
and unlocked positions.

[0190]The housing 40 is universal among the different lock assemblies. In
other words, the housing 40 is not specific to a particular lock type
design, and the housing 40 can be used in the KIK lock assembly 10, the
IC lock assembly 310, and the mortise lock assembly 1010 without
modification. For example, the housing 40 can be removed from the KIK
lock assembly 10 and used in the IC lock assembly 310 or the mortise lock
assembly 1010. The housing 40 accommodates the components that are used
in KIK lock assemblies, IC lock assemblies, and mortise lock assemblies
without additional manufacturing processes (e.g., machining, tooling,
etc.). Generally, the housing 40 can be transferred from any one of the
KIK lock assembly 10, the IC lock assembly 310, and the mortise lock
assembly 1010 to another of the KIK lock assembly 10, the IC lock
assembly 310, and the mortise lock assembly 1010 without modification,
and without added manufacturing processes or tooling. The transferable
housing 40 reduces the complexity of lock assemblies, and limits costs of
manufacturing by limiting the number of different components that are
needed for different lock types.

[0191]In some constructions, the housing 40 and the plug 45 that are used
in the KIK lock assembly 10 can be universal among the different lock
assemblies. The housing 40 and the plug 45 can accommodate the different
characteristics and components of the KIK lock assembly 10, the IC lock
assembly 310, and the mortise lock assembly 1010 without modification to
reduce the complexity of lock assemblies, and to limit costs of
manufacturing.

[0192]FIGS. 48-56 show an assembly housing 1420, a cam member 1430, and a
retainer clip 1435 for use with the lock assemblies 10, 310, 1010, or
other lock assemblies. For the sake of brevity, the assembly housing
1420, the cam member 1430, and the retainer clip 1435 are described below
with regard to the lock assembly 310 and the IC lock cylinder assembly
325 (see FIGS. 6-23). It should be understood that the features of the
assembly housing 1420 described herein may be incorporated into assembly
housings of other lock assemblies (e.g., key-in-knob lock assemblies,
mortise lock assemblies, etc.). Furthermore, it should be understood that
the cam member 1430 and the retainer clip 1435 are generally universal
components that may be used with various lock assemblies.

[0193]As illustrated in FIGS. 48-50, the assembly housing 1420 includes a
rim 1440 that defines a first end of the assembly housing 1420 and that
abuts a surface of the door, and a housing body 1445 that extends from
the rim 1440 and that defines a second end of the assembly housing 1420.
The housing body 1445 engages the inside of the door, and defines a
second end of the assembly housing 1420 that is opposite the rim 1440.
The housing body 1445 includes diametrically opposed locking channels
1450 that can be engaged by fasteners (e.g., screws, bolts, etc.) in the
door to lock the assembly housing 1420 from rotation after the assembly
housing 1420 is engaged with the door.

[0194]The assembly housing 1420 also includes a cavity 1455, a locking
hole 1457, and a housing opening or aperture 1460. The cavity 1455 has a
substantially "figure-eight" shaped cross-section that is defined by a
first interior surface 1465 and a second interior surface 1470. As
illustrated in FIGS. 49 and 50, the upper portion of the cavity 1455
defined by the first interior surface 1465 extends from the first end
toward the second end of the assembly housing 1420. A cam hole 1475 that
is defined by a surface 1477 extends through the second end of the
assembly housing 1420, and is in communication with the lower portion of
the cavity 1455 that is defined by the second interior surface 1470.

[0195]The locking hole 1457 is disposed in the first interior surface 1465
adjacent the second end of the assembly housing 1420. The housing
aperture 1460 extends through the housing body 1445 in communication with
the cavity 1455, and also extends from the second end of the assembly
housing 1420 toward the first end.

[0196]FIGS. 49 and 50 show that the cam member 1430 is coupled to the
second end of the assembly housing 1420. The cam member 1430 extends
through the cam hole 1475 to engage the plug 360, and is rotatable with
the plug 360 to transfer rotation from the plug 360 to a lock chassis
(not shown) in the door. The cam member 1430 is formed as a single piece
from any suitable material (e.g., metal, plastic, etc.) using any
suitable manufacturing processes (e.g., zinc die casting, molding,
machining, etc.).

[0197]FIGS. 51-54 show that the cam member 1430 includes a cam body 1535
that defines a lobe or latch engagement member 1540 and a transition or
bearing surface 1545. The lobe 1540 is engageable with the lock chassis
to move a latch in the door to lock and unlock the door in response to
rotation of the plug 360. The bearing surface 1545 spaces the cam body
1535 from the housing body 1445 to permit substantially unimpeded
rotation of the cam member 1430 relative to the housing body 1445.

[0198]The cam member 1430 also includes an alignment bearing 1550 that
extends outward from the cam body 1535 and a drive element or engagement
member 1555 that extends outward from the alignment bearing 1550. The
alignment bearing 1550 includes a first surface 1560 and a second surface
1565. The first surface 1560 is engageable with the surface 1477 that
defines the cam hole 1475 to maintain axial alignment of the drive
element 1555 with the plug 360 so that rotational movement of the plug
360 can be transferred to the lock chassis via the cam member 1430.

[0199]The drive element 1555 is substantially cylindrical and is in
communication with the cavity 1455 such that the drive element 1555 can
be engaged with the IC lock cylinder assembly 325 within the end of the
plug 360. The drive element 1555 includes substantially cylindrical outer
surfaces 1567 that engage an inner surface of the plug 360. As shown in
FIGS. 51-54, the drive element 1555 also includes opposed engagement
recesses 1570, opposed retainer slots 1575, and a clearance slot or
groove 1580. The opposed engagement recesses 1570 and the opposed
retainer slots 1575 are symmetrical about an axis 1585 that extends
through the cam member 1430.

[0200]With regard to FIGS. 51, 52, and 54, the engagement recesses 1570
are separated from each other by a drive element portion 1587, and extend
along the drive element 1555 substantially perpendicular to the axis
1585. The engagement recesses 1570 are defined by curved surfaces 1590
that extend from an outer end of the drive element 1555 to the alignment
bearing 1550 adjacent an inner end of the drive element 1555. The curved
surfaces 1590 are engageable by the alignment pin 1530 to transfer
rotation of the plug 360 to the cam member 1430 so that the door can be
locked and unlocked.

[0201]FIGS. 53 and 54 show that the retainer slots 1575 extend through the
drive element 1555 adjacent the alignment bearing 1550 at an inner end of
the drive element 1555 substantially parallel to or along the axis 1585.
The retainer slots 1575 are symmetrically opposed from each other about
the axis 1585. The retainer slots 1575 have rectangular cross-sections,
and are defined by the second surface 1565 of the alignment bearing 1550,
bridge surfaces 1595 of the drive element 1555, and drive element
surfaces 1600 of the drive element 1555 that are disposed opposite the
second surface 1565. FIGS. 51-54 show that the retainer slots 1575 are in
communication with the engagement recesses 1570, and are shaped to
receive the retainer clip 1435.

[0202]The clearance groove 1580 is disposed in one of the outer surfaces
1567 of the drive element 1555 (i.e., along the bottom of the drive
element 1555 as viewed in FIG. 53), and extends through the drive element
1555 from the outer end to the inner end substantially perpendicular to
the axis 1585. The clearance groove 1580 is a shallow recess that
receives a retainer clip removal tool (not shown) that is operable to
detach the retainer clip 1435 from the cam member 1430.

[0203]FIGS. 49 and 50 show that the retainer clip 1435 is attached to the
cam member 1430 to retain the cam member 1430 in engagement with the
assembly housing 1420 while allowing rotation of the cam member 1430
relative to the assembly housing 1420. FIGS. 55 and 56 show that the
retainer clip 1435 is substantially "U"-shaped. In the illustrated
construction, the retainer clip 1435 is formed from a relatively thin
material that has spring-like characteristics (e.g., metal, plastic,
etc.). In other constructions, the retainer clip 1435 can be formed from
other suitable materials.

[0204]FIGS. 55 and 56 show that the retainer clip 1435 includes a first
surface 1605, a second surface 1610 that is opposite the first surface
1605, a central portion 1615, and two opposed retainer arms 1620. The
central portion 1615 defines a tool slot 1625 that is substantially
aligned with the clearance groove 1580 when the retainer clip 1435 is
attached to the cam member 1430. The tool slot 1625 is formed to receive
an end of the retainer clip removal tool to facilitate removal of the
retainer clip 1435 from the cam member 1430. The central portion 1615
also includes opposed corner portions 1630 that are disposed on opposite
sides of the tool slot 1625 and that engage one of the cylindrical
surfaces 1567 of the drive element 1555 when the retainer clip 1435 is
attached to the cam member 1430 to provide the gap that allows insertion
of the removal tool into the tool slot 1625.

[0205]The opposed retainer arms 1620 extend from the central portion 1615
and are spaced apart from each other such that the retainer arms 1620
define a channel 1635. Each retainer arm 1620 includes an extension 1640
that is disposed adjacent an end of the corresponding retainer arm 1620,
and an arcuate portion 1645 that is disposed adjacent a middle of the
corresponding retainer arm 1620. As illustrated in FIG. 56, each
extension 1640 is positioned adjacent an end of the associated arcuate
portion 1645. Generally, the extensions 1640 are spaced from the central
portion 1615 so that the extensions 1640 are substantially engaged with
the engagement recesses 1570 after attachment of the retainer clip 1435
to the cam member 1430. As illustrated in FIG. 55, each extension 1640 is
defined by a curved surface profile 1650 that protrudes from an inward
edge of the retainer arm 1620 into the channel 1635. In other
constructions, the extensions 1640 can be defined by other profile
shapes.

[0206]The arcuate portions 1645 are raised resistance arcs of the retainer
clip 1435, and include curved surface profiles 1655 that extend beyond a
plane defined by the first surface 1605. In some constructions, the
curved surface profile 1655 of each arcuate portion 1645 engages the
corresponding drive element surface 1600 of the drive element 1555, which
holds the cam member 1430 in engagement with the housing body 1445. In
these constructions, the second surface 1610 of the retainer clip 1435
engages the second surface 1565 of the alignment bearing 1550. In other
constructions, the curved surface profiles 1655 can engage the second
surface 1565 of the alignment bearing 1550 to hold the cam member 1430 in
engagement with the housing body 1445. In these constructions, the first
surface 1605 of the retainer clip 1435 engages the corresponding drive
element surface 1600 of the drive element 1555. Generally, the arcuate
portions 1645 resist rotation of the cam member 1430 when the IC lock
cylinder assembly 325 is removed from the assembly housing 1420, which in
turn inhibits undesired movement of the latch between the locked and
unlocked positions.

[0207]The lock assembly 310 is assembled by engaging the cam member 1430
with the assembly housing 1420 via the cam hole 1475, and attaching the
retainer clip 1435 to the cam member 1430 via the retainer slots 1575.
After the drive element 1555 is inserted into the assembly housing 1420,
the retainer clip 1435 is inserted into the assembly housing 1420 through
the housing aperture 1460 in the bottom of the assembly housing 1420.
When the retainer clip 1435 is attached to the cam member 1430, the
retainer arms 1620 engage the drive element 1555 within the retainer
slots 1575. The extensions 1640 slide along the bridge surfaces 1595 and
snap into engagement with the curved surfaces 1590 of the engagement
recesses 1570 to securely attach the retainer clip 1435 to the cam member
1430.

[0208]After the extensions 1640 snap into place, the curved surface
profiles 1650 of the extensions 1640 resist removal of the retainer clip
1435 from the cam member 1430 without the use of the retainer clip 1435
removal tool. Depending on the orientation of the retainer clip 1435 upon
insertion into the retainer slots 1575 (i.e., whether the arcuate
portions 1645 engage the drive element surfaces 1600, or the second
surface 1565 of the alignment bearing 1550), the second surface 1610 of
the retainer clip 1435 is engaged with one of the second surface 1565 and
the drive element surfaces 1600. Engagement of the arcuate portions 1645
with the cam member 1430 limits movement of the cam member 1430 into and
out of the assembly housing 1420, and also limits undesired rotation of
the cam member 1430.

[0209]The IC lock cylinder assembly 325 can be inserted into the cavity
1455 before or after the cam member 1430 is attached to the assembly
housing 1420. When the IC lock cylinder assembly 325 is inserted into the
cavity 1455, the plug 360 engages the cam member 1430 within one of the
engagement recesses 1570. Engagement of the cam member 1430 with the plug
360 causes rotation of the cam member 1430 to depend on rotation of the
plug 360.

[0210]In operation of the lock assembly 310, the appropriate key 315 is
inserted into the key slot 130, which allows the plug 360 to be rotated
between the locked position and the unlocked position. Rotation of the
plug 360 using the appropriate key 315 rotates the drive element 1555,
which in turn causes rotation of the lobe 1540. The lobe 1540 is rotated
and engaged with the lock chassis to move the latch between the locked
and unlocked positions. The arcuate portions 1645 resist rotation of the
cam member 1430 during removal of the IC lock cylinder assembly 325 to
inhibit undesired movement of the latch between the locked and unlocked
positions. In this manner, the retainer clip 1435 opposes rotation of the
cam member 1430 that can be caused by removal of the IC lock cylinder
assembly 325 from the assembly housing 1420.

[0211]The retainer clip 1435 is disengaged from the assembly housing 1420
by inserting the retainer clip 1435 removal tool into the cavity 1455,
into the clearance groove 1580, and into engagement with the tool slot
1625 of the retainer clip 1435. In the illustrated construction, a
generally downward force is applied to the retainer clip 1435 using the
removal tool to disengage the extensions 1640 from engagement recesses
1570. After the extensions 1640 are disengaged from the engagement
recesses 1570, the retainer clip 1435 is removed from the retainer slots
1575 through the housing aperture 1460 in the bottom of the assembly
housing 1420. The cam member 1430 can be detached from the assembly
housing 1420 after the retainer clip 1435 is removed from the drive
element 1555.

[0212]Generally, the one-piece cam member 1430 and the retainer clip 1435
simplify assembly and disassembly of the lock assembly 310, as well as
operation of the lock assembly 310. During assembly of the lock assembly
310, the cam member 1430 and the retainer clip 1435 allow fewer
components to be used to transfer rotation from the plug 360 to the lock
chassis without additional manufacturing processes. During operation of
the lock assembly 310, the cam member 1430 and the retainer clip 1435
transfer rotational movement of the plug 360 to the lock chassis without
susceptibility of the attachment between the cam member 1430 and the
assembly housing 1420 becoming loose over time. The single-piece cam
member 1430 and the retainer clip 1435 reduce the complexity of lock
assembly 310, and limit costs of manufacturing by limiting the number of
different components that are needed to transfer rotation of the plug 360
to the lock chassis.

[0213]Various features and advantages of the invention are set forth in
the following claims.